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Metal makes up a huge part of the world’s total landscape. It’s involved in so many parts of our life, and if you’re a fan of this site, you’re probably manipulating it regularly as a professional or a hobbyist. Spot welding is a technique commonly used to join two pieces of metal, especially sheet metal. This can be for a temporary weld, or a weld on thin material like auto body panels.
Here we’ll talk about one small but basic tools that are handy when you have to remove those spot welds.
Quick Take: Best Spot Weld Cutters
Here are the top spot welders available:
- Kauthof RM1905 3/8” Double Sided Rotary Spot Weld Cutter
- Grizzly T10296 Double End Spot Weld Cutter
- KCC Industries DR4402 Value Pack
What Is a Spot Welding
Spot welding is often used with certain types of sheet metal or wire mesh. It’s not such a great method for thicker structural steel because the heat flows into the surrounding metal more freely. Spot welding is seen on sheet metal goods like metal buckets or on auto panels.
Aluminum alloys can be spot welded but since aluminum has higher thermal and electrical conductivity, it requires higher welding currents. For this, you’d need larger, more powerful, and more expensive welding transformers. It can be done even though it’s not recommended. The same goes for copper or copper alloys.
Automobile manufacturing industry is the most common area that spot welding is used. It’s the most common way to weld the sheet metal panels to form the outside of the car. Spot welding can even be completely automated. It’s one of the uses robotics on the assembly line.
Spot welding may even be used in the orthodontist's clinic, where small-scale spot welding equipment is used when resizing metal "molar bands". But we don’t recommend you try to use a spot weld cutter to adjust your own braces!
Another application of spot welding is in the manufacture of batteries. The cells in batteries are joined by spot welding thin nickel straps to the battery terminals. Spot welding can prevent the battery from getting too hot, which is a possibility if you use conventional soldering instead.
The advantages of resistance spot welding are various. It makes for a quicker process time, for one. It also uses a lower amount of consumables, such as brazing materials, solder, or welding rods. Since it’s using less energy and material, it’s cleaner and more environmentally friendly. Finally, it produces very reliable joints.
What To Look For In A Spot Weld Remover
Now that we have an idea of how resistance spot welding is done, we know that spot weld metal interfaces will be very sturdy and reliable. But some projects call for the removal or tearing apart of soldered joints. This is very likely if you work with car restoration or any other projects that involve plenty of sheet metal with spot welds.
Spot welds need thorough care when being removed, especially when you want to save as much of the original metal as you possibly can. There are several methods to remove spot welds, but the difference lies in the tools you have to accomplish the task.
A good spot weld remover helps you easily cut around the spot weld, freeing up the panel while keeping the underlying panel intact.
On the market today, double-ended spot weld cutters are more common. These cutters quickly remove spot welds without damaging the underlying panel. With double ends, you can cut twice as many holes as with single-ended spot cutters.
The spot weld cutter you are looking for will leave very few burrs when you cut and will leave the holes drilled with them extremely smooth. This will make it far easier to continue your work on the piece of metal you’re working on.
Spot weld cutters usually come in kits. It is best to get your spot weld cutters in sets of three or more. The extra blades or bits mean there will be no down time in your project as you wait for the blade to get sharpened. It is also ideal to get a kit with different-sized blades.
Some kits will also come with centering tips. These centering tips are very useful for guiding the bit into the center of the spot weld for an accurate and smooth cut.
Quick Comparison Chart of the Best Spot Weld Removers
KCC Industries DR4402 Value Pack
Blair 11096 Cutter Set
Kaufhof RM1905 3/8 Inch Double Sided Rotary Spot
SG Tool Aid 18000
Grizzly T10296 Double End
Reviews of the Best Spot Weld Cutters
Here, we offer you helpful information on some of the best spot weld cutters in the market. Read on for aid on picking out the most suitable tools for your work styles and metal projects.
Blair Spotweld Cutters are the Professional's choice for removing spot welds. The Blair 11096 is one of their hottest-selling kits.
This kit comes with three (3) 3/8” Cutters, an arbor with a “skip-proof” pilot, and an extra pilot. Blair Spotweld Cutters guarantees fast cutting of spot welds. The 3/8” double-ended blades cut more holes efficiently and will fit 3/8” and ½” hand-held drill chucks.
The blades are manufactured from a high-grade steel which does seem to keep them sharper longer. These bits are also designed to only cut through the outer layer of sheet metal and keeps the underlying layer undamaged. That will help you when you want to weld new sheet metal back onto it.
The bit has what is called an “annular design” that makes for drilling smooth and burr-free holes. This is a high-end spot weld cutter kit which is a little more expensive. But because of the high-grade material used to manufacture the tools, the Blair 11096 is top on the best spot weld cutters’ “value for the money” list.
KCC Industries is a veteran-owned welding tools company in the industry which puts a high premium on customer satisfaction.
The DR4402 value pack includes 2 Arbors with Cutting Blades plus 2 Replacement Cutting Blades. You get durable double-ended 3/8” high-speed rotary metal cutting blades manufactured from high-quality heat-resistant steel. 3/8” is an ideal size for removing spot welds. This is great for quickly separating spot-weld panels leaving no distortions.
The 1/4" Standard Size Arbor with Flats helps eliminate spinning in the chuck (fits 1/4" and larger drills).
This precision spot weld cutter does not come as part of a kit, but it’s one you definitely need to consider, nonetheless. It is a double-sided 3/8” rotary cutter blade that will fit most ¼” drills as well. When one side goes dull, you do not need to purchase a replacement spot cutter… you simply flip the bit over on its arbor assembly.
Kauthof’s spot weld cutters are known for drilling out spot welds accurately. They leave a clean hole without needing to file away any metal burrs. It’s a spot weld bit that not only cuts clean but is non-invasive, too. This means that it does not distort the pieces of sheet metal that you are drilling through. That’s critical for any spot weld cutter.
This is another standalone spot weld cutter that offers value for time and money. It’s a double-sided 3/8” rotary cutter blade that will fit most ¼” drills, too. When one end loses its sharpness, you just flip the bit around without needing to go out and buy a new spot cutter.
It is very affordable and will last you a long time. However, it’s best to use it at low drill speeds and with cutting oil to help prolong its lifespan.
The Grizzly T10296 is one of the highest-rated spot welders that you will find on the market today. It does a great job in making sure it only cuts as deeply as you need it, so it won’t cut through the two pieces of sheet metal that are welded together. It will efficiently cut through the top piece of sheet metal but not the underlying piece. This makes it significantly easier to attach a new piece of sheet metal to the underlying panel.
This spot-weld cutter comes in a very useful kit. It includes six 3/8″ double-ended cutters and three spring-loaded centering tips. The centering tips are handy for guiding the blade into the center of the spot weld so the cut is smooth and precise.
The kit itself is lightweight and compact enough to fit even small toolbox compartments. It’s moderately priced but with all the extras in the kit, the Grizzly T10296 will give you great value for your money.
Resistance spot welding is used in tons of types of projects involving sheet metal. It’s a particular favorite for work on patching panels on your car or restoring that old classic.
Whether you are into automobile restoration, furniture art, or any other field dealing with spot welds, you’ll definitely want a quality spot-weld remover to be able to cut out the section you’re replaced without harming the rest of your work piece.