Producing the thinnest cut in bodywork.

[1960bus]

I need to cut a piece about 12 inches long off my car for access to a panel and then butt weld it back on. I've been using 1mm cutting blades on my grinder for years and I know you can get them in 0.8mm. Does anyone make anything thinner? I'd like to get as close to zero gap as possible when re welding 0.5mm or less would work I think.

 

[711jrp]

Dremel ? they have some very thin blades.

 

[rikrobson]

3" cut off blades are a lot thinner

 

[BrokenBiker]

die grinder or dremel type elctric tool would be my suggestion too, can get some very narrow discs for them. have you had a problem welding a 1mm gap on bodywork before? i find the gap helps to stop distortion when the weld cools as if there is no gap the joint usually shows where there is a small ridge

 

[1960bus]

I was thinking of tigging it back on with zero gap. I did have a dremel lent it to a mate... You know the rest.

 

[Burdekin]

How about just cutting a new panel to weld back in and just use the 1mm discs you have.

 

[BrokenBiker]

thought you would be migging it as its car work...didnt realise you were thinking of tigging it ...no gap is probably best then but as said above it might just be easier to make a new panel if it isnt anything complicated

 

[gaz_moose]

when I was in the bodywork business I used to use an air saw to chop cars up.

 

[Shox Dr]

You'll tear your hair out using a dremel. You'll use millions of discs, it will take forever, and you'll end up with a poor cut line.

.8mm slitting disc, don't think you can get thinner

 

[PhillipM]

Flexovit do some 0.7mm discs and they're smooth as butter to cut with, I wouldn't even consider a dremel.

 

[Mr shiney]

I would MIG it back in and .8mm is plenty thin enough for that. TIG will give you distortion and fit problems in my experience.

 

[BrokenBiker]

I was thinking of tigging it back on with zero gap. I did have a dremel lent it to a mate... You know the rest.

do you have a mig you could use as this is going to be the better process for this application

 

[the snooper]

I think too smaller gap may cause more distortion as the panel heats up and expands as you weld and would have no gap to expand into to would deform

 

[1960bus]

I think I'll go with the 0.7mm or even 1mm disc on a grinder and mig then. I hate the grinding with mig though so started using tig a lot when I can reach the back to planish.

 

[Wendelspanswick]

Like you say TIG with zero gap is good if you have access to the back to planish but MIG and the thin metal technique with a small gap is better at reducing distortion if working from a single side.

 

[graffian]

Air saw, or hand hacksaw I suppose, I have done it loads of times.

 

[HMB]

.75mm slitting discs are available. Think mine are abracs make.