DD-67L-1719-TCOOL - Last Updated: 4/7/2022
Page 4 of 17
© Driven Diesel, LLC
Cutting the Center Support Out
This will probably be the most difficult section for most installers. The air conditioning condenser is
very close to where we need to cut, so care needs to be taken to prevent damage to the condenser.
We have supplied (2) cable saws in the kit as we have determined that all of the necessary cuts can
be made with no risk to the condenser with this tool. You are welcome to use other tools, just be
mindful of the condenser as damaging it will not be an inexpensive fix.
The cable saw is a disposable tool with a finite life, especially when used on the fiberglass reinforced
plastic you will be cutting. How you use it will determine if it completes the job for you or fails
prematurely. Please take the following tips seriously, and be patient, this is not a quick process!
STROKE
: Use the full length of the cable. Each pass should be “from handle to handle” so that you
wear the entire cable evenly. If you use short strokes, you will focus all of the wear in a small space
and the cable will fail more quickly. See Figures 14 & 15 for a visual guide on this.
SPEED
: The cable saw motion should be slow and controlled. The faster you try to go, the hotter
the cable gets and the quicker it will fail. If you try to saw too quickly, you will actually see the cable
turn blue from the heat. We advise about 1-2 full seconds for each alternating stroke. This will seem
slow, but once it starts to cut, it will move through the material steadily.
TENSION
: As you make your cut, you need to keep constant tension on both ends of the saw. At
the same time, you need to let the cable do the work. Do NOT pull too hard on the cable, this will
just cause it to break. You need just enough tension to keep both ends of the cable straight at all
times, again, let the saw do the work. Notice in the pictures that we are using only 1-2 fingers on
each end of the cable saw.
DURABILITY AND SAFETY
: The cable saws can continue to be used up to the point that the cable
breaks. Even when the cable starts to fray, it will continue to cut.
BE VERY CAREFUL WHEN
HANDLING THE CABLE AFTER YOU’VE STARTED USING THE SAW, FRAYS IN THE CABLE
ARE SHARP AND WILL EASILY PIERCE THE SKIN. GLOVES ARE RECOMMENDED WHEN
HANDLING CABLE SAWS!
13.
Using Figure 16 as a guide, cut the center bottom section of the center support first. You will
have to carefully feed the saw through the triangle shaped windows. Hold the saw so that it
glides flat on the surface next to the support and cuts the support as low as possible.
14.
Using Figure 17 as a guide, cut the top of the center support next. Notice the slight upward
angle of the cable in our picture, this is intentional and recommended. When you complete
the first cut through the top, the remaining stub will be angled.
15.
Using Figure 18 as a guide, cut through the (2) angled “wings” at the bottom of the center
support.
16.
If you have been careful with the cable saws, you should now be able to return to the angled
stub that remains from making the top cut. We have found that there is a notch on the back
that you can use the cable saw in that will allow you to make a more level second cut.
17.
Once you are done cutting the center support out, we recommend using coarse grit sand
paper (a palm sander works well) to clean up the areas where you made the cuts. Use some
finer grit sand paper to clean up the appearance if desired. We do not recommend using high
speed grinders as they generate a significant amount of heat and tend to melt the material.
Make sure you protect the air conditioning condenser during this step! See Figure 19.
