Cutting out rot in body panels - tool worth having???

[GRW]

I'd like ALL the tools given the chance even I I don't know how to use em properly.
A little plasma would be lovely - but I know my faffing around doesn't justify half the kit I do have if I'm honest with myself - so I'm forcing myself to be sensible (For now at least ).
A die grinder tho has more uses I think.
An electric Nibbler again has crossed my mind... but like the plasma I don't think I'd use it much.

 

[Burdekin]

Grinder and invest in some welding blankets.

 

[Ubique]

obviously you've missed the point completely, in simple terms there are appropriate tools for each job, a plasma torch is appropriate for some, but not all. Same as a sledge hammer will crack a walnut, it's unlikely going to be your first choice of method is it. Again it's not a question of avoiding spending time to do the job properly, I consider doing that job properly means using the most appropriate tool for the task in hand, preferring to avoid uneccessary work when I can use other tools which involves less clean up / less fire risk, but heyho somefolk will always find the hard way, rather than the easy option, if they want to make life difficult for themselves, that's their choice.

I haven't missed any 'point', I've just disregarded your opinion. In a bodyshop where they have the full range of tools to choose from, for cutting out irregularly shaped parts with poor access and wanting to minimise mechanical stress, a plasma cutter would be ideal for the task, especially in areas where there is likely to be multiple 'skins'. Not the hard way at all, sometimes the most appropriate way involves more preparatory work - a bit like the old chippies saying of 'measure twice, cut once'.

 

[GRW]

Grinder and invest in some welding blankets.

I do have (one) welding blanket.
The particular repair spot I'm thinking of though isn't ideal to use a grinder on - hence wondering what else might be the kiddie

 

[bricol]

If you are worried about plasma sparks setting something on fire, then exactly the same worry will apply when welding it back together - protect or remove the problem area - I tend to remove all trim, carpets, sound deadening - less to catch fire, less damage, and just easier and cleaner to work.

I have a small plasma, and on car bodywork, it doesn't require much air - on thicker stuff, then my little compressor can't keep up.

WRT the original question - you don't have to use a 4" disc on a 4" grinder - I keep a selection of partially worn discs for working in small areas, for more delicate cuts. You can be quite precise with where and how you cut with a grinder and a 1mm wide slitting disc.

I have a small section of decent tin-snips with varying angles of jaws and handles that can get in all sorts of spots.

I have a small nibbler attachment for a drill - I used to use it a lot 30yrs ago - the quantity of small metal chips it produces used to annoy me - especially when they landed inside bits where they then refused to come back out - I just knew they were sitting there creating a starting point for rust. Then thin slitting discs either appeared, or I became aware of them - I've maybe picked the nibbler up a couple of times in the last 20 yrs. Useful for the odd thing.

 

[DAPPH]

Buy an all in one plasma cutter then you have an all in one plasma cutter after the job's done & dusted. It's how you build up your stock of proven useful tools.

 

[Rkweld]

I have used plasma, it is good for the right job. Maybe see if you can try one somewhere on the type of material you will use it on. If i was doing hobby body work again I would probably look towards a motorised nibbler or a some sort of saw, reciprocating or similar. Could you use a slitting saw rather than a fiber compound type cutting disc in a grinder/die grinder. Die grinders consume a lot of air by the way. If your dremels pack up have you looked at the foredem type electric die grinders or drills??

 

[GRW]

Buy an all in one plasma cutter then you have an all in one plasma cutter after the job's done & dusted. It's how you build up your stock of proven useful tools.

Don't tempt me lol

 

[Rkweld]

https://vevor.co.uk/products/update...Dtec_M8_gCobajD3tIyMjTeAEKly6oRhoC1SsQAvD_BwE

This is a copy of a foredem i think.

 

[mr haynes]

Tbh i would just stick a metal blade in your jigsaw or use snips

 

[GRW]

If you are worried about plasma sparks setting something on fire, then exactly the same worry will apply when welding it back together - protect or remove the problem area - I tend to remove all trim, carpets, sound deadening - less to catch fire, less damage, and just easier and cleaner to work.

I have a small plasma, and on car bodywork, it doesn't require much air - on thicker stuff, then my little compressor can't keep up.

WRT the original question - you don't have to use a 4" disc on a 4" grinder - I keep a selection of partially worn discs for working in small areas, for more delicate cuts. You can be quite precise with where and how you cut with a grinder and a 1mm wide slitting disc.

I have a small section of decent tin-snips with varying angles of jaws and handles that can get in all sorts of spots.

I have a small nibbler attachment for a drill - I used to use it a lot 30yrs ago - the quantity of small metal chips it produces used to annoy me - especially when they landed inside bits where they then refused to come back out - I just knew they were sitting there creating a starting point for rust. Then thin slitting discs either appeared, or I became aware of them - I've maybe picked the nibbler up a couple of times in the last 20 yrs. Useful for the odd thing.

I just guessed that a Plasma in having an Arc cutting right through the metal - would be far more likely to cause a heat/fire problem than tack-stitching a small plate in at low Amps with the MiG.

(I'm aware that mine is an unqualified opinion, having only seen a Plasma used a few times, not on thin metal, and never used one, so I'm aware I might well be wrong.... I often am )

 

[RonA]

I’ve cut out rotten bodywork using a standard woodworking jigsaw in the past but using a shortened hacksaw blade ground to fit in the jigsaw blade holder. If the jigsaw is multi speed all the better.
It’s also a good way of getting 100% use out of the blade ends which don’t get used in normal usage
RonA

 

[GRW]

https://vevor.co.uk/products/update...Dtec_M8_gCobajD3tIyMjTeAEKly6oRhoC1SsQAvD_BwE

This is a copy of a foredem i think.

That looks like a handy wee gadget

 

[GRW]

I’ve cut out rotten bodywork using a standard woodworking jigsaw in the past but using a shortened hacksaw blade ground to fit in the jigsaw blade holder. If the jigsaw is multi speed all the better.
It’s also a good way of getting 100% use out of the blade ends which don’t get used in normal usage
RonA

Neat idea! I suppose the throw of a jigsaw isn't anything like as long as a blade - so a cut-down blade for shallow work .... works!

 

[W.olly]

I have done a lot on cars over the years and only ever used a 115mm grinder or plasma. Prefer the plasma, so easy and quick. And good for tight spaces.

 

[Burdekin]

I do have (one) welding blanket.
The particular repair spot I'm thinking of though isn't ideal to use a grinder on - hence wondering what else might be the kiddie

I also have a finger belt sander which works well for awkward positions once you get to the stage you can't cut any more out with a grinder.

 

[RonA]

Neat idea! I suppose the throw of a jigsaw isn't anything like as long as a blade - so a cut-down blade for shallow work .... works!

If you do use this idea, don't forget to arrange blade so it cuts on the upstroke RonA

 

[MCKDAVID]

like I've said, I have no issue with using plasma on a car shell, but only if it's the most appropriate option. Bearing in mind the OP was refering to a roof section, so if it's quicker to use cold cutting methods before the risk of fire / spark damage, or taking longer to remove trim or arrange fire blankets to protect the interior, etc, I'll take the easier option every time, and there are plenty of options to choose from. If it's a bare shell restoration, aye obviously makes little difference.

As for comparing plasma cutting to welding, not sure their directly comparable, take any plasma torch, cut thin sheet, and see how far the stream of sparks goes and how much more they're concentrated. Now take the welder on a low amperage for the same thin sheet and see how few sparks in comparison. Yes you'll still have sparks, but nowhere near as concentrated or projected. In terms of risk, given the same conditions, I'd say plasma was more likely to cause damage than the same welder, given the higher concentration and force of the discharge, but agreed they both need to be protected so I suppose it's a pointless argument in real terms.

 

[bert]

The only tools I use is the 4.5" grinder and 2 die grinders one straight on 90 degrees.

Not found a job welding up cars that can't be done with those yet.

 

[GRW]

The section I'm on about is a rear corner pillar... so it's double-skinned, curved and only accessible from the outside.
In theory on my old LDV there's not a lot to set fire to in that area... but there is glassfibre insulation in side the van (all clad in of course) , plus there is the glassfibre roof close by.
Now, being careful and having worked o the van a fair bit (inc. Welding) I'm not too concerned about torching the thing or damaging it mig welding a patch in.... but I was a bit worried about the idea of cutting out with something as hot as a Plasma.
Hence thinking I'd go for a gentler method.
It's not a big patch and so mechanising the hell out of it to save labour isn't as high priority as getting it done without wrecking it.
I'm not a craftsman and it'll never be a repair of cad restorer standard - I ain't that good!
So tools that help my limited skills get the job done is the thing