Spot Weld Trick

[Explorer]

Learned a new trick yesterday. Friend came over to help replace a core support on a vehicle. He brought a die grinder with a 1/4" thick 3" grinding wheel. Ground out all the spot welds in the time it would have taken me to drill two or three.

 

[bmc69]

I've always ground most of them too..you develop a feel for the true extent of the actual spot weld coverage at each location (watching how the metal heats up and where) and some of them are rather odd/random shapes that the round spotweld cutters just won't cut out right.

 

[rjrobin2002]

I use a 4 1/2" angle grinder and a 40 grit flapper grinder or a regular griding disk. I c a n remove 50 welds in the time it takes to grind one.

 

[BoureeOne]

Now here is your challenge. Try those on the spot welds holding the rear fenders on. Yes, on a nice open area where you can get the grinder in there it is great....

 

[allenfahey]

Learned a new trick yesterday. Friend came over to help replace a core support on a vehicle. He brought a die grinder with a 1/4" thick 3" grinding wheel. Ground out all the spot welds in the time it would have taken me to drill two or three.

This is how every body man I've worked with does it. They grind the weld and the remaining sheet metal just pops off. We work on flat rate in the auto body industry, the faster we get it done the more we make! There is also less chance you go too deep with the spot weld bit. If the area is hard to reach the tool truck (and Harbor Freight) sell extended reach cut off tools. Most body men take the guard off.

 

[rastiss]

Been using this style setup daily for 20+ years. It has always made everyone nervous with no guard. Never been hurt by it. I actually run 2, one with the thick wheel and the other with a 1/32 thick wheel. And then of course, my spot weld drill. If you are replacing the panel, rough cut around with a panel splitter on your air hammer so you can get to the welds easier.

 

[bmc69]

I just came up with a great idear! I have three tubs here and various other parts of tubs that I want to take apart, combine, reassemble and repair with new metal to make two good bodies.

I propose that I set them up and invite everyone to participate in a competition to determine who's technique is the best.

Just tell me what date(s) are best for everyone.

 

[rastiss]

Contest to be held in Wichita falls Texas. Entry fees go to shop owner...

 

[Explorer]

The second picture is the one he was using. Lot easier to get in tight places than regular grinder. Thanks rastiss. Tink I'm going to find the wheel, should work well will my angle grinder too.

 

[rastiss]

I like the reach with this setup way better than a regular" cutoff tool". But you need common sense to run it. Stay out of saw line, etc......

 

[AZ73]

I tried grinding, but I ended up using this instead:

http://www.harborfreight.com/3-8-eighth-inch-double-sided-rotary-spot-weld-cutter-95343.html

It was fast and created the new hole I used to weld the new pieces on with.

 

[allenfahey]

I tried grinding, but I ended up using this instead:

http://www.harborfreight.com/3-8-eighth-inch-double-sided-rotary-spot-weld-cutter-95343.html

It was fast and created the new hole I used to weld the new pieces on with.

This is just my opinion....
The problem with that is it puts an unnecessary hole in the parent metal.

When you use the cut off wheel method you remove the top piece. Drill and grind the new metal. Apply weld thru primer. Lay new metal with the hole in it onto the old metal (parent metal). Spot weld it into the old metal. That is one of the ways to do it. Another way is panel bond and another is using a inverter spot welder which is very $$$$ but the best weld for body work. IMHO

 

[DrLathrop]

I assume you are just grinding through the top metal piece & through the spot weld at the same time? There would be no reusing the panels at that point.

 

[Mill KNOB]

I tried grinding, but I ended up using this instead:

http://www.harborfreight.com/3-8-eighth-inch-double-sided-rotary-spot-weld-cutter-95343.html

It was fast and created the new hole I used to weld the new pieces on with.

These are what I have always used and am using now on my build. Went by Harborfreight this weekend and pick up a couple.

To me they are the way to go. Never try the gridding wheel. But will try it out.

 

[Pa PITT]

.. OK What do we say.. With out Pictures IT'S worthless. If I can't see your girlfriend I don't want her!!
.. I'm about to work on removing a a Broken off wind shield frame.. & It has about 25 spot welds. I backed up to wait until I can get to Harbor FREIGHT. But now If all I need to do is get out my 4.5 SIDE GRINDER and get thru the top surface.. that will be thrown away anyway.. I can do this & it does seen to me much faster. Than those spot welder removers..
... OH Send pictures of your girl friend to my PM BOX.
... MUCH O CARACAS .. THANKS

 

[clarrance]

.. OK What do we say.. With out Pictures IT'S worthless. If I can't see your girlfriend I don't want her!!
.. I'm about to work on removing a a Broken off wind shield frame.. & It has about 25 spot welds. I backed up to wait until I can get to Harbor FREIGHT. But now If all I need to do is get out my 4.5 SIDE GRINDER and get thru the top surface.. that will be thrown away anyway.. I can do this & it does seen to me much faster. Than those spot welder removers..
... OH Send pictures of your girl friend to my PM BOX.
... MUCH O CARACAS .. THANKS

I'll bet there is waaaay more than 25 spot welds on that windshield frame.

 

[bax]

a lot of the body guys are using this tool. I was not sure about it until a guy showed me how good it worked on spotwelds. pretty cool
https://www.youtube.com/watch?v=zDIq8psx8hk

 

[DrLathrop]

I'll bet there is waaaay more than 25 spot welds on that windshield frame.

I am working on a windshield frame removal right now as well & more than 25 on just the passenger side. Random spots as well. I bet the factory welder was drunk as some are an inch apart & some places have 3-4 welds per inch. I will be making the replacement removable with flat head screws countersunk. Have been looking for pictures of this option but have had no luck yet.

 

[myclsic69]

I am working on a windshield frame removal right now as well & more than 25 on just the passenger side. Random spots as well. I bet the factory welder was drunk as some are an inch apart & some places have 3-4 welds per inch. I will be making the replacement removable with flat head screws countersunk. Have been looking for pictures of this option but have had no luck yet.

No Pictures, But i went w/ the Stainless Flat head Bolts, countersunk the Frame Hinge, added Sealant , Nuts and washers from the Bottom side, no issues and would do that again, but I preped the Surface of Both Metals w/ P&M industries Silver to rust proof the area.
Oh by the way, I lost count on the spot welds I removed.

 

[SC74]

I ways used the small hole saw style spot weld bits. If you give it a tiny pilot hole it won't walk on you. I've removed thousands of spot welds with these and as long as you don't put too much pressure on it the bits will last for many welds. I won't lie though - I have ground them out too!