What is the best method to cut holes for side markers and backup light housings? Some people talk about plasma cutters others use di grinders. I really don’t want to make a mess of my fender and the rear of the car. Any suggestions? PS I would like to do this my self and avoid taking the car to a body shop if at all possible.

68 i would highly recommend a cut off tool you know that uses the thin rocks. they have worked great for me in the past.i,ve replaced my rear panel and gonna have to cut-out for the b/u lites and this is what i,ll
be using.

IT COST TO GO FAST
HOW DAM* FAST DO YOU WANT TO GO

A cut-off tool will work but you must be very carefull not to heat up the adjacent metal excessively. This will cause the sheet metal to warp. Plasma cutters do work great and if you temp out the area you want to remove, a good shop could do it for you in a matter of minutes, leaving a very clean line, with no risk of heat warpage.
Good Luck

I personally use a snap-on AT-190 air saw. I dont leave home with out it.

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67 Camaro SS Conv.
70 Challenger R/T Conv.

Thanks for all the great input. I talked to a local shop and they would do it and use a plasma cutter. Any thoughts on using a nibbler?

I tried cutting some holes on an old hood. Plasma works great but if you are worried about your paint don't use plasma. I also tried a cutting wheel if you go slow paint is ok but it will take forever. Best thing I found is to drill a 3/8”hole at each corner then I used a pneumatic saw. Paint is ok and the cuts are quick. Cleaned it up with a file looks perfect. ragtopman you are right on. Thanks to every one, this is a great site.