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OK, I rented the MIG welder this weekend and practiced on scrap sheet metal. I feel confident that, with more practice, I can perform welding of floor repairs and other patches. However, in practicing I have discovered that cutting the sheet metal can be the real nasty part. I used an abrasive cutting wheel and it worked ok for the small amount of work that I needed it for. I just can't see using it to cut out rusted floors, trunk sections, inner rockers, etc.

Does anyone else have other suggestions?

I know that a plasma cutter would be ideal, but am trying to keep cost down and I don't think I could rent one.

Help!!!
 

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I like using the 3" thin cut off wheels, however a good recepricating saw does a good job on thick sheet metal which is hard to get at with a cutoff tool. I've done quarters, trunk floors, drop offs and tail light panels with just these two tools. Good luck
 
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Some more tools that work in various applications are a good scroll saw. The scroll saw is good for cutting pieces from stock and for cutting any old metal off the car which you can access with the saw. If you have air, an air hammer with a sheet metal cutting bit is a good one to quickly get the old floor pan cut out. An air cutoff tool is really handy. Even an angle grinder with a cutting blade is usefull. You'll also need to drill out spot welds so a spot weld drill is usefull. For torque boxes a cutting torch is fast but an grinder can do that job too.

Adrien.

65 GT Coupe, dismantled waiting for resto.
67 Restomod Coupe, in assy.
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The other folks covered it well. I've used a 3" cut off wheel in an electric die grinder - not ideal. If I can find the right cutoff wheel to fit my small 4" grinder that would be better.

I've also used metal snips but wouldn't recommend it for removing a quarter panel!

Regards,

Dean T

Shikatta Ga Nai - "It cannot be helped"
 

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As much as possible I would take the time and drill out the original spot welds where I could using a spot weld cutter. Leaves (once ground down) a nice place to attach the new panel

Jeff Speegle
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Hey guys, don't you read Mustang Monthly? Use a reciprocating saw, or "Sawzall". Once you get the hang of it, it really works wonders. I bought a reconditioned Super Sawzall from Harbor Freight for $130.00! Plasma cutters are too expensive.
 

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Sawsall works well. Also a scroll saw with a good metal cutting blade works. Look at the Idea of an air driven nibbler.
It cuts a small circle and you just push it through the metal and it cuts a line. Harbour Freight has them for about $40 .

My son got me into this and I'm having a ball
65 fastback, 289, 3 speed, Holly 1850, Edelbrock intake. SSB front disks in a box, Canadian Mustang "real big kit" suspension in alot of boxes,
Right now lots of boxes!!!!!!!!!!!!!!
 

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Does the nibbler distort the metal at all? Will it work for cutting 1/4s etc where you have a long cut on a basically flat surface that will be seen? I have seen an attachment that can be put on a drill to do the same but the air tool appeals to me.

Food for thought: Just think, If your weren't where you are you would be somewhere else.
 

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I once cut up an entire Volkswagen Beetle with a sawzall using a few fine tooth metal cutting blades. Worked great!

Years ago, I opened up the wheel wells on an old Dodge van using a jigsaw with metal cutting blades. And the cut was absolutely great. Deburred with a hand file after cutting. Had no metel warpage at all.

Dang! Just when I got used to being "strange", I became a "newbie", then a "tire-kicker". Now I'm a "beginner"?.....hmmmmmm...where do I start?
 
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I think with patiance, you can cut it with just about any of the tools suggested. Some are going to take more time than others. I prefer a plasma cutter.

http://members.tripod.com/tangdar/
'67 Coupe project car (Did I say project car? I meant pile of rust)
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