I need to enlarge the hole in my topcap where the fuel fill goes, the old one broke and the new and improved piece Legend provided me is shaped differently and a little bigger. Any help would be greatly appreciated.

Dremel tool or jig saw for straight lines. I just used both enlarging my fuel access panel.

drill rasp. use this on a lot of things just be careful about controlling it.

http://power-tools.hardwarestore.com/54-...aign=googlebase

I have a RotoZip tool with a table attachment that works like a router. Makes this type of work much easier to control.

Carbide bit on a drill mini sawsall rasp several ways to do it

+1

I ended up using a jig saw on slow speed and taking my time, went pretty well hardest part was hooking the hoses back up. chipped the gelcoat a little when I tried to reinstall the screws but redrilled with a bigger bit and got them in without chipping anymore. The chip I did make was covered by the fuel filler.

My choice would be an air saw.

I see you already got it, but for enlarging holes (like thru-hulls, etc) or fine detail work I use a drill rasp or a small sanding drum attachment for my drill. For larger/rougher holes, I use a jigsaw. And for major cut-out work, I bust out the 4.5" grinder with 36grit.

support

Thanks for everyones help, wont be as nervous next time.

Might want to ask around on Bassboatcentral as well. A lot of good info on there as well as here.