Auto Body Guys! Question About Sheetmetal Spot-Weld Removal

[Metallitubby]

I am in no-way-shape-or-form an automotive body guy, so I'll ask some of the experts here:

What is your prefered way of removing spot-welds? Having watched a couple YooToob videos, there seems to be a variety of methods and tools used. What do you prefer?

Drill?
Grind?
Sand?
Cut?



*Picture for example

 

[pancholasvegas]

Depends on the position & what you are doing but all of the above can be used if that's on hand! Do you have a set of panel splitters / chisels? Those are very helpful.

If you are trying to save one of the panels for re-use, I really don't like to drill through both of them - I like to use a cut off wheel on a die grinder and cut back just until you're through and then peel it off. Time consuming, but does the least damage to the panel you're saving.

I don't mind the spot-weld cutters as shown, those work fine too - I like to have several on hand.

Belt file can work just as fine too, but I usually stick with the die grinder and cut-off wheel. @MP&C has some examples shown in one of his threads on panel replacement, that's where I learned.

If you don't care that much and are in a hurry, just send a drill bit through and then follow with a step bit big enough to remove both layers.

 

[Shitbox]

Are you planning on reusing the panel that you’re removing? If you are use a rotobroch like the picture you showed. If you’re not saving the panel and it’s of no use to anyone else, I just use a 3” x 3/16 grinding disc in a die grinder to knock the weld down enough that it started to blue(do a test on some scrap parts so you know about when that is first) then hit it with a seam splitter and it’ll separate easily. Band file will also work the same way if you’re more comfortable with that.

 

[Metallitubby]

Are you planning on reusing the panel that you’re removing?

No.

 

[MP&C]

 

[Rockable]

Like Robert, if I'm not interested in saving the panel, I grind it out with a cutoff wheel or air file. If I'm trying to save it, I drill it with different tools depending on the job.

 

[Shitbox]

Since you’re not saving the panel I’d grind them off. The video @MP&C posted shows exactly the way I said(but ya know, better since you can see exactly what I meant).

 

[ejwan]

Bandfile with the 3m cubitron belt

 

[Metallitubby]

Excellent video find!

I should note that I've already used the spot-weld cutter bits, and have done exactly what the narrator of the video said about going too far into the second panel. Luckily, I am only using a portion of the 12 spot-welds per side of the panel on the replacement panel going in its place.

 

[Metallitubby]

Bandfile with the 3m cubitron belt

I purchased an Ingersoll version yesterday, just for this! If nothing else, I'll have another useful tool.

 

[nadogail]

i have used a Spot Facing tool that looks like a miniature end.mill with pilot that is powered by cordless drill

 

[ejwan]

I am no professional but have done my fair share of panel replacement.

You will be satisfied. No sparks compared to the grinder and more control. Just keep an eye out for the slight outline of primer or corrosion that appears once you go thru the trash panel. You can use a flathead screw driver to split the layers as you go.

I dislike the spot weld drill bit as it can go off center and you can also drill right thru the panel.

 

[Metallitubby]

I dislike the spot weld drill bit as it can go off center and you can also drill right thru the panel.

So I've noticed. Like I mentioned; Luckily I'm not reusing the top panel, and much of the panel supporting it will be removed as well.