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Automotive: Panel & Spot-Weld Removal
Short, stiff stubby drills from 3/16" to 1/2" for drilling out spot welds, and thin 3" and 4" cut-off wheels for die grinders, to get a damaged panel loose.
Cutting out a damaged panel
Taking a panel off starts with finding its spot welds and drilling them out without chewing the flange underneath. This step holds the bits for that and the wheels for cutting a panel free where the repair procedure allows.
- Stubby (mechanics-length) drills from 3/16" to 1/2", plus the number and letter sizes in that range, in 135° black oxide and HD styles from Triumph, Tru-Cut and Titan. The short length keeps the bit stiff and on the weld.
- Die grinder cut-off wheels in 3" and 4" diameters, 1/32" to 1/8" thick, in Walter ZIP, ALLSTEEL and ZIP ALU, with 1/4", 3/8" or 5/8" arbor holes.
Drilling out spot welds
Boron and other ultra-high-strength steels dull ordinary bits quickly, and the vehicle maker's repair procedure says where welds may be drilled or cut and where they may not. Follow it. Start the bit square on the weld, use steady pressure with a drop of cutting oil, and stop as soon as it breaks through the top sheet so the lower flange stays intact. Wear eye protection and use the guard on any cutting wheel.
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Common questions
What size bit drills out a spot weld?
Spot welds on body panels are typically 6 to 8 mm across, about 1/4" to 5/16", so a bit in that range is a common start. Go by the weld you can see on the flange, and by the vehicle maker's procedure.
Will these bits drill boron steel?
Boron and ultra-high-strength steels are very hard and dull HSS bits quickly. Use low speed, steady pressure and cutting oil, and expect to change bits more often. Check the repair procedure for where welds may be drilled.
Will the cut-off wheels fit my die grinder?
Match the arbor hole and the speed. Each wheel lists its diameter, thickness and arbor hole, and the tool's top speed must not exceed the wheel's rated speed. Use a mandrel that fits the hole.
Buying for a crew?
Call 833-438-6657, 8 AM to 4 PM MST. We know the parts, not just the part numbers.