[Lionelgee]

Hello All,

What sort of tool would you recommend to cut through some lengths of weld that are on the end seam of at least two sheet metal panels?

The attached photograph shows the join between the plenum or cowl, the front door pillar and another piece of steel. The join or end seam is length of weld - not a spot weld.

I used a reciprocating saw after I had made space for the blade. This worked really well on the passenger side. However, due to the extent of the rust on the driver's side - instead of cutting through the weld, the blade started to track through a couple of layers of sheet metal. I would like to have more control the next time I face having to cut similar runs of weld on the end seam.

I have to remove the plenum because of extensive rust along the top length of the firewall and plenum joint. Plus, there is more rust where the plenum joins the front door pillar. The rust has eaten away the right angled ends of the plenum and along the bottom of the windscreen sill.

Decades ago the lower windscreen rubber must have started to leak. Water then found a home in the joint between the plenum and the front door pillar and it kept this area moist. This formed a breeding ground for lots and lots of rust.

Kind regards
Lionel