Purist, close your eyes. I want to put custom headlights in my 71 but the back of the bulbs are to big to fit the hole in the pot metal fender extension. I've seen people with these bulbs in there cars but don't know how they did it. Was wondering if I got a big metal cutting hole saw to drill the hole bigger. Anybody tried this?

Yeah. I have a similar issue on my 67. I need a 3" or 4" metal hole saw to fit the back of the housing into the radiator support. (havent done it yet)... Not a hude deal, just make sure its centered when you cut.... the hole saw will drill through the pot metal and leave a cleaner opening then trying to cut it...

How much bigger does it need to go? It might be easier to take a barrel sander and open the hole. For a holes to work it needs a pilot hole. To use a hole saw where a existing hole is already there you'll need to mount it to a wood block so you can extablish a pilot hole. It won't be easy.

I have tried drilling the pot metal headlight extensions on my 71 and it drills like butter. So smooth and easy.
Grinding on the other hand isnt so easy, at least in my experience.
From what I have tried it loads up the paper/disk and loses its functionality very quickly.

That's what drill presses, Bridgeports and jigs are for.

Hey, you guys gave me an idea. If I cut a peice of wood the size of the existing hole and put that on the pilot bit, that would align the larger hole saw as I drill it out. It needs to be about an inch bigger so sanding would take awhile. Thanks dudes!