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I started drilling out the spot welds on the drivers trunk floor today. There are quite a few 'hard to reach' welds, especially along the taillight panel. My drill is too big to drill straight down. How do you guys do this? Do you just drill at an angle and try not to take out too much of the metal below, or do you do something else? From what I can tell, this is just the beginning, there are going to be lots of tough ones.
Thanks,
Gregg
 

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There may be no "perfect" solution. I had some luck using carbide grinding bits with a high speed 1/4" grinder. The carbide bits are sold for head porting and stuff. One I found most useful is an extra long one (like 6") with a small ball shape on the end. You can use it at any angle, but it will usually make a bigger hole than you would prefer.
I got mine at a swap meet for $15. The shorter ones usually sell 3 for $10. The only other places I've seen them are at machine shop supply houses. Expect their prices to be about double. An internet search might turn up something reasonably priced.
If you don't have the appropriate grinder, you can use your drill. It's much less efficient and kind of hard on the drill, but doable. A drill spins too slowly and isn't designed to handle "side-loading". I have a sloppy loose drill I used to use for this. Cost me $5 from a yard sale. I broke down and bought the proper electric grinder and it turned out to be worth every dime. I love that thing, but never touch it unless I've got my safety glasses on.
 
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I use an ainexpensive 90 degree head on my drill.

I also use a more brute force method of getting out my 90 degree grinder with a cut off wheel and just have at it.

Hammer and cold chisel can work to.

You will do some damage regardless. You will have some repairs to the pieces of metal that you keep. Its unavoidable.
 

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Hey Gregg, you need a right angle drill or die grinder. I have a milwaukee right angle drill, but that mother is big and heavy when you are doing alot of work.
Sears has the die grinders, I think the are around 80 bucks. If you have a Craftsman Club card (free item!) you can get 10% off during Club days!!
 

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Yo Gregg!
FB is doing fine , got the cowl welded up and I'm in the process of putting the engine compartment aprons on. Had to slow down this week, kid Brother is getting hitched. I promised Mom I'd pressure wash and stain her deck (it's big about 20x90).
I'm also ordering my hydraulic TO bearing from David Kees ( www.4speedtoploaders.com ) . All is well.
Keep me informed on the vert. If I can hepl find parts or something, let me know.
 
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