Thread: Cutting into painted fiberglass, need a few suggestions

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As long as you have plenty of area being covered by that new light bucket, probably a cut off wheel would work the best. A jig saw or Sawzall blade will vibrate that fender, possibly causing a big chip in the gel coat if the blade was to catch going one direction while the fender is vibrating another direction. Mask it off really well with multiple layers of tape so if that wheel decides to take off, you are 'covered'. Dress it with a die grinder and carbide burr afterwards. Here's a page from McMaster Carr with several different kinds of cut off wheels. I would just get a couple of the high performance or long life versions and have at it - McMaster-Carr

If you need to drill fiberglass, they also have special 'plastic' drill bits that work great in 'glass - I have a few, not cheap though