Topic: Fender bolt holes in new sheet metal

[Danoh1]

Is there a tool or process to recreate these holes for the fender bolt nut clips?  In the past I’ve used my Dremel, but the result is generally “rough”.

[jwc66k]

There is a tool class called a "metal nibblers". Some are manual (usually for up to 0.035 in thick steel), others are compressed air operated (up to 0.062 in thick steel, just a guess). For the rectangular shaped holes with the quarter round corners, you would drill a center hole to fit the nibbler, drill the corners, and use the nibbler to get the rest of the material removed. Holes like what you are dealing with, are punched by a single die on a 30 ton stamping press.
Jim

[1967 eight barrel]

I did mine differently as Ford did not stamp the U nut holes for the fenders in the front replacement aprons. on either side.
I made a pattern and laid them out. I drilled the center out and used an rotary file in my die grinder to shape the openings.
It's the fastest and easiest way to do them.  It takes a little finesse to control the angle die grinder. If the RPM gets real slow it causes the file to be difficult to control.
There are a lot of different shapes. A small drum shape works nicely.

[Danoh1]

Good idea on drilling the corners. Thanks.