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Best way to cut bumper for etc 3.5" race intercooler.

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Use a high speed cutting wheel device of some sort as to not flake the paint. If you're trying to preserve the paint, painters tape can act as a stencil and help keep the paint from chipping and flaking.
 
I measured and put painter's tape around the edges. Then I scribed a cut line. Then I went to town with a Dremel and cut-off reinforced wheel. Didn't take too long. I slapped the core on the car and test fitted it before I cleaned up the edges.
 
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