How do you remove spot welds?

[out2kayak]

I thought I would start working on removing the rear quarter on the passenger side of the Chevelle. A previous owner cut it across the top and did not weld things back together. As well, the bottom (behind the rear tire) was rotted out. Finally, just behind the door the panel had a decent size crack.

The question I had was how to remove the spot welds. I've tried the fancy spot weld cutting bits and was underwhelmed with them. They broke often and I have quite a few spot welds to cut through.

Looking at:


I have the sander / grinder he is using (yes, I realize that the presenter leaves much to be desired). I tried that and it worked, but it seemed like it was taking a long time.

I then tried use the plasma cutter to remove the spot welds, as shown at:



So far, the plasma cutter has done an excellent job. It does take a steady hand, though. I did put a couple of pin holes in the base panel when my attention was not fully on the work, but those will easily fill with the TIG. If I simply go along the edge of the two panels pointing outward, then bringing it into the panel, I can do it without any base metal damage (even less than what the video shows).

[kevin_l]

A quality spot weld cutter makes all the difference.

[rocketrod]

^^ What he said. I have that same one and I have drilled out about 100 spot welds with a single cutter.

You should also buy a Seam Buster.
https://www.amazon.com/Steck-Manufac.../dp/B000JFJMJ6

Originally Posted by kevin_l

A quality spot weld cutter makes all the difference.

[dhutton]

I knock them down with a small 3M weld grinding disc in a die grinder followed by a hit with a very sharp cold chisel bit in my air chisel. I like the plasma cutter idea but i don't have one. I hate drilling out spot welds. This method is very quick.

Don

[Ketzer]

Same advice on a good quality cutter, but the big thing for me is getting myself in the right frame of mind. It is tedious as hell, no way around that. No matter how careful I try to be, I always mangle the flange somewhere and have to do a bunch of work on it. I've even had to just give up before and chop the old flange off completely, remake that, then bring in the new panel....

[kush69]

try a air belt sander you would be surprised how easy it grinds weld and pretty precise at that I have a cheap astro one and some 60 grit belts and just use the tip of it

[kush69]

also use the 3m belts they last much longer

[DOOM]

Originally Posted by kevin_l

A quality spot weld cutter makes all the difference.

We use both methods at my shop . The belt works great I like to drill them but if you have a MATCO tool distributor around I prefer there brand over the Blair. They seem to last much longer.