Disclaimer: This isnt a how-to, just providing some info that might help others.
Tools:
Harbor Freight 4" corded angle grinder [HF #60373]
SAS adjustable Face Shield [HF #46526]
Safety Glasses
Dust mask
Diablo 4"x .040" (1mm) Metal Cut Off Wheel [Home Depot #247559]
Blue painters tape
Moving blankets [HF]
Plastic
Exacto knife
2 testosterone filled sacs
Tool Notes:
Cut Off Wheel - I purchased 2 but you'll only need 1.
Safety - I used a face shield and safety glasses. I used a dust mask and some ear plugs too. Make sure you re-adjust the angle grinder shield to best protect you.
Exacto knife - Used to cut and peel off the template guide lines. I spent a good amount of time doing this.
Prep Notes:
Blankets/Plastic - You'll want to cover the entire engine bay and from the top the windshield forward. The aluminum dust gets everywhere.
Masking - I taped off a huge swath of each side for the side vents. Only on the top, I did not mask the underside of the hood.
Cutting Notes:
General - Let the tool do the work. Dont push to vigoursly trying to cut through faster. For each straight edge I made some back and forth motions, slowly and carefully, across the entire length to start a groove/cut line. I then plunged about 1/4 of the way from a corner, backed into the corner then proceeded the rest of the length.
Corners - The corners are a bit tough. Just keep an eye on your cut line and dont overshoot. Most of the corners turned out ok but 2 of them I had to take a longer look at to do them properly.
Finishing notes:
I vacuumed all the dust up from the enginer bay and all around. I used a dremel with a cylindrcal sanding disc to smooth out the edges. Although this was good I am going to get a small file as I need to smooth our the space between the ribs that were cut. I will also paint anything cut and let it dry before finishing the install.
I spent about 2 weeks agonizing over using different angle grinders or a jigsaw. I went with the angle grinder because of the many videos I watched and it was noted it was more likely faster.
