OK, here is the first part of the step by step installation tutorial for mannequin "A".
I will do this in three sections:
1. Mannequin Prep
2. Adapter Installation
3. Finishing the installation
MANNEQUIN PREP
1. Position the cutout template as shown. Move it around until all edges of the template fit snugly against the surface. Due to the shape it will pretty much locate itself. It really can't move side to side so it's mainly just adjusting it up and down until it fits snug.
2. Hold the template firmly in the center, and using a fine point sharpie, trace around the outside of the template. This will be the final hole size.
You can also trace around the inside of the template - this will be a guide for drilling the holes.
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For the next steps, these are the tools I used:
Electric drill (variable speed recommended)
1/8" drill bit
Dremel multi purpose cutting bit:
http://www.homedepot.com/p/Dremel-1-8-i ... /202263174
Rotary file bit:
http://www.lowes.com/pd_227515-68082-02 ... 53916&Ntt=
3. Using a 1/8" drill bit, drill holes close together 3/8"-1/2" apart keeping inside the cutout line as shown. This goes pretty quickly - only took me about 6 minutes.
4. Using the Dremel cutting bit, connect the holes to make the cutout. I just held the mannequin between my legs and used both hands and slow speed with the drill for control. This also goes quickly - about 5 minutes.
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5. Using the rotary file bit, carefully grind off material to the finished cutout line. Leave some of the line showing - do not grind past the line. Again, for control I held the mannequin between my legs and used both hands with the drill. About 10-15 minutes to complete.
6. Roughen the surface approx. 1/2" around the opening with 60 grit sandpaper. Another 10 minutes.
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IMPORTANT SAFETY STEP!
At this point before moving on, carefully inspect the area around the opening inside the mannequin for any sharp strands of fiberglass that may be present.
The adapter projects inside and safely covers the hole but it never hurts to check and make sure there are no sharp strands that could poke through the sleeve and cause you injury.
If any exist then remove them with sandpaper before proceeding.