Cut List + Printable Drilling Template (Pelican Sidewalls)
Print at 100% (actual size, no “fit to page”). Check the calibration bar and 1″ square before drilling.
Cut List (defaults you can tweak below)
| Item | Qty | Hole/Cutout | Pilot → Final | Notes |
|---|---|---|---|---|
| Warm-air duct collar (75 mm) | 1 | Ø 80 mm | 3 mm → step to 80 mm | Fits most 75 mm duct rings (often ~80 mm cut) |
| Exhaust thru-hull | 1 | Ø 32 mm | 3 mm → step to 32 mm | Match your stainless hardware; exhaust hose ~24 mm |
| Combustion intake thru-hull | 1 | Ø 25 mm | 3 mm → step to 25 mm | Separate from exhaust; faces away from people |
| Fuel QD (CPC NS4) panel | 1 | Ø 24 mm | 3 mm → step to 24 mm | NS4 panel opening 0.945″ ≈ 24.0 mm |
| 12 V DC cable gland (PG13.5) | 1 | Ø 20.5 mm | 3 mm → step to 20.5 mm | PG13.5 hole 20.5 mm (PG21 = 28.3 mm) |
| Return-air grille (rect) | 1 | 120×80 mm | Drill corners 6 mm → jigsaw | 4× corner screws Ø4 mm @ 8 mm in |
If you’re using a different QD or gland, plug its datasheet hole size below and reprint.
Template Controls (mm)
Offsets are from the left and bottom edges of the panel on the template.
Preview / Print Page
Calibration: the long bar should measure 100 mm and the square should be exactly 1 inch.
Tips:
• Tape the template to the case, align to bottom/edge.
• Center-punch each crosshair, drill 3 mm pilot, then step up to size.
• Deburr inside/outside. Fit hardware with gaskets/RTV as required.
Defaults shown are safe starting points to avoid typical ribs on Pelican 1500/1520-class cases, but always open your case and confirm internal clearances before drilling. For a different fuel QD or cable gland, plug the datasheet hole size above and regenerate.