Cut outs for Small Rubber trunk mat

[lreppond]

I have a late US model w113 (build date 11/70).  I recently purchased new rubber mats for the trunk but need help marking and cutting out holes in the small mat that is under the spare tire and jack brackets.  I have no idea of what to use to get a sharp even cut line nor how to accurately mark it off.  (I no longer have the original mat.)

Does anyone know the diameter of the hole for the post on which the spare rests?   Is there a template available to get this right?  Any help or pointers will be greatly appreciated.  I have only one try to get this right! Attached is a pic of how the small mat was delivered as well as the large mat in place. 

[49er]

Good Morning, Here are a few pictures of my mat showing the location and diameter of the spare tire bracket. Hope this was what you were looking for and let me know if you need anything else

John

[lreppond]

Thanks John.  This is exactly what I was looking for! So far I’ve made a paper template, reinforced the edges and cut out areas with three layers of painters tape for added rigidity.  I’ll fit the template first, transfer the final cutouts to the mat and then cut.  I plan on using a scalpel and metal straight edge.  I’ll have to cut the circle free hand unless I can find a lid or round object that's the correct diameter.   

[66andBlue]

....  I’ll have to cut the circle free hand unless I can find a lid or round object that's the correct diameter.   

I have used an OLFA ratchet cutter with great success. You just need patience and go around the circle many times to eventually cut through vinyl or rubber.
https://www.ebay.com/itm/162722553384
 There are several other OLFA compass types on Amazon with wheel cutters. Those work very well with thinner material.
https://www.amazon.com/OLFA-9911-Compass-Circle-Cutter/dp/B000BK7NWC?

[BobH]

Hello Len, once you've finished cutting out it would be handy to put the template in the tech manual for others when they need it

Thanks

[waltklatt]

Irrepond,
I can take my original one from my 220SL and make a paper template for you. 
I cn mail you the full sized template, if you provide me an address.
Send me a PM if you are interested.

Thanks,
Walter Klatt
1967 220SL diesel
1969 280SE
2003 Beetle TDI
2005 Honda Element

[lreppond]

Thank you Walter.  That’s very kind of you but I’m almost finished with the mat.  Using John’s (49er) measurements, I was able to fabricate a template, transfer it to the mat and begin cutting it out.  Waiting for a circular cutter from Amazon to complete the cut out for the spare tire post.  Will upload a pic when it’s completed. 

[Bonnyboy]

Very nice -  you do good work.

[lreppond]

I finally completed the cut outs for the small trunk mat.  Although time consuming to get it laid out correctly, the rubber itself was easy to cut. Because it had a lot of stretch I was able to forego cutting several pieces out to the edge as shown on John’s (49er) mat.  Overall very pleased with the outcome.

Btw, I purchased both mats from Nelson at Vintage Euro Parts. I paid $200 for the set.

[66andBlue]

What kind of circular cutter did you buy?

[lreppond]

What kind of circular cutter did you buy?

I got this one from Amazon.  It has a very sharp blade and it relatively easy to use.  I was going to purchase the Olfa you suggested but I thought this might work better.  Getting the cutter centered was my biggest issue. You really can’t see the centering pin so you’ve gotta do it rather blindly.

[49er]

Hello Len, Your mat looks great and everything worked out OK. My measurements were done in a hurry and so glad they were accurate enough for you. Good luck tomorrow and hope they can get that stubborn gas cap off with minimally invasive means. I think I will leave mine unlocked from now on as I never leave the car unattended. That was a wakeup call for me and I'm sure others.

John

[waltklatt]

Well done Irrepond!
Looks factory cut.
Now another job is finished.
What is the next project?  Gas cap?
How's that going?

Walter
1967 220SL diesel
1969 280SE
2003 Beetle TDI
2005 Honda Element

[AndrewB]

Beautiful work Len, can you publish the dimensions of your template and the tools you used in the Technical Manual ?

Regards
Andrew

[yves]

+1😉

[lreppond]

I would be more than happy to share this info but it might be of limited usefulness.  The reason why these mats aren’t fully cut is because each car is a  little different.  Compare the upper most cutout on my mat vs 49er’s.  They’re in completely different position relative to the round cutout.  Also although I can measure each cutout size I have no idea how to show the angle. 

I used a new blade in a box cutter and a metal straight edge for the straight cuts and the NT circle cutter for the round cutout. I used a standard wide mouth canning jar lid for the circular cutout dimension. It was 3-9/16” or about 9.05 cm in diameter.