I said I would post this when I had time., Splitting spot welds Options

[rick 918-S]

This is the method I use to split spot welds. Some guys use the Blair spot weld drills. I have nothing against them but when I had my shop I found that my employees had no concern for the cost of the bits or the way they were using them. They would break the hardened cutters and toss them like a used rubber on prom night or they would over drill and end up weakening the attachment for the new panel.


If used correctly the Blair is a nice tool. The proper use is to use the cutter to score the sacrificial panel then use a air chisel or a hand chisel to split the panel. Nobody uses it that way. At least no one I've ever had the experience of seeing use the tool.

So, I imposed this method in my shop and would spot check the results to be sure my guys were doing it correctly.

This is my way not the only way.

First I trim away as much of the panel as I can and usually try to leave only the spot weld strip.

Run a grinder over the spot weld strip to show the spot welds.





Then I use a 3" grinder and grind the spot welds. My goal is to thin the metal not grind through.



Here is what it looks like after I grind.



I like to use a screw driver that I have sharpened to a chisel end. I work it in and around the spot welds until I get it split.



Here is what is left after I split the spots. Notice the actual spot welds are still showing on the body.





After grinding and prepping the body for the replacement panel.



This is not the fastest way but this is how I prevent damaging the car and weakening the metal I want to re-use on the body.