Uploaded January 2018 | Updated September 2026, 1 hour ago
This skill video demonstrates how to cut an access opening in the skin of an aircraft (power saw).
Three-sided Method
1. Select appropriate cut-in area. Some aircraft may have cut-in marks on the aircraft fuselage.
2. Create an access hole near the upper corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the cutting blade into the hole and make a horizontal cut across the upper side of the rectangle.
4. Make vertical cuts from the ends of the horizontal cut down to the lower “cut-in” marks.
5. Fold the flap of aircraft skin downward toward the ground.
6. Pad jagged edges if time allows.
Four-sided Method
NOTE: This method must be used on composite materials.
1. Locate the “cut-in” marks on the aircraft fuselage. These marks outline a rectangle that is free of obstacles inside the fuselage or within the skin of the aircraft.
2. Create an access hole near the lower corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the cutting blade into the hole and make a horizontal cut across the lower side of the rectangle.
NOTE: When completely cutting an access/egress panel, the bottom cut should be your first cut to avoid the saw blade or rescue tool from binding (caused by the weight of the door).
4. Make vertical cuts from the ends of the horizontal cut upward to the upper edge of the cut-in area.
5. Make a horizontal cut across the upper side of the rectangle.
6. Remove the rectangle of aircraft skin.
7. Pad jagged edges if time allows.
This skill video demonstrates how to cut an access opening in the skin of an aircraft (power saw).
Three-sided Method
1. Select appropriate cut-in area. Some aircraft may have cut-in marks on the aircraft fuselage.
2. Create an access hole near the upper corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the cutting blade into the hole and make a horizontal cut across the upper side of the rectangle.
4. Make vertical cuts from the ends of the horizontal cut down to the lower “cut-in” marks.
5. Fold the flap of aircraft skin downward toward the ground.
6. Pad jagged edges if time allows.
Four-sided Method
NOTE: This method must be used on composite materials.
1. Locate the “cut-in” marks on the aircraft fuselage. These marks outline a rectangle that is free of obstacles inside the fuselage or within the skin of the aircraft.
2. Create an access hole near the lower corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the cutting blade into the hole and make a horizontal cut across the lower side of the rectangle.
NOTE: When completely cutting an access/egress panel, the bottom cut should be your first cut to avoid the saw blade or rescue tool from binding (caused by the weight of the door).
4. Make vertical cuts from the ends of the horizontal cut upward to the upper edge of the cut-in area.
5. Make a horizontal cut across the upper side of the rectangle.
6. Remove the rectangle of aircraft skin.
7. Pad jagged edges if time allows.
