Cutting Through A Weld

[MikePA]

My wife took a right hand turn a little too tight and dented the aluminum fender on our horse trailer. Pushed the fender into the tire and I had to use a digging iron to get enough leverage to bend it off the tire. I'd like to remove the fender and see if I can straighten it out and/or install a new one.

What's the best tool to use to cut through the welds? At the front and rear of the fender it's TIG welded to running boards. Across the top, it's TIG welded to the body of the trailer.

Even if I don't remove the fender, I have to trim it so it's further away from the tire. What's the best tool to use for that?

BTW, I have an air compressor so an air tool is an option.

 

[RedRocker]

If you can grind them there will be a little less damage than with a torch. You can use a radiac type wheel on a die grinder too as well as a sawzall or jig saw.

 

[Highbeam]

A plasma cutter makes quick work of aluminum and the cut is narrow so reattachment can look real good. I usually grind out welds with either the 4.5" angle griner or the air powered die grinder if I need to be careful. Aluminum is funny to grind, it tends to jamb up the grit of the wheel.

 

[MikePA]

Are you guys taking about this --------> Die grinder.
I noticed they make an angle die grinder as well.

And this --------> Cut off wheel.

I'd love to get a plasma cutter, but the price..... /forums/images/graemlins/crazy.gif

 

[hazmat]

Assuming it is stitch welded, use a 4 or 7" angle grinder. See attached ($30 at the depot, great for ocassional use)

 

[hazmat]

Use the perimeter (vs the "flat") of the disc to cut thru the welds. Pic 2

 

[MadReferee]

Since you have an air compressor that die grinder will work. Just make sure the cutting blade you have is rated for the rpm that the die grinder can generate. Don't forget to wear proper face and eye protection. A shattered cutting blade can and will win the argument. /forums/images/graemlins/blush.gif

I have used both a die grinder and a 4 1/2" grinder with a cutting wheel. What you use will depend on material thickness and how much room you have to maneuver around to make the cut.

 

[MikePA]

Thanks for all the great ideas! I'll ponder this a while, which will keep my wife off the road. If she's not on the road, she won't be able to do this a fourth time! Yep, my bride has done this three times, same fender. /forums/images/graemlins/frown.gif First time was a minor dent (didn't get it fixed), second time she hit so hard the axle, wheel, tire and fender had to be replaced. Now this. The fender is pretty thick aluminum.

Attached is a picture of the fender (left fender, she hit the right fender) that I cropped from a picture of the entire trailer. The fender is welded where I've made the red lines. Getting into the corner where the fender and running board meet the body of the trailer might be difficult with a large angle grinder.

Maybe I'll just tell her to take it back to the place we bought it (they're made there, too) and ask them to fix it (second time in 6 months). The harassment she'd get from them might be worth it. /forums/images/graemlins/tongue.gif

 

[Bird]

Mike, the little air powered Ingersoll-Rand die grinder you showed is a very handy tool and would probably outlast your kids and quite likely your grandkids. Even the cheap off brands of that straight style will last a long time. I like the little angle die grinders, like this one but if not properly cared for and lubricated, the gearing in the front end to make the turn can be damaged, and in some cases the parts cost more than the tool's worth. If you get one of the angle models, it should have what looks like a tiny ball bearing on the side of the head. That's a grease fitting that you grease with a needle nosed grease gun. If you go to the link above and click on "enlarge photo", you'll see that ball (grease fitting) clearly.

 

[RedRocker]

Oops, the aluminum didn't register. You can buy special wheels for an angle grinder for aluminum, do not use a standard disc for steel, you won't get very far. Same with the cut off wheel, they're for steel. The grinder wheels I've used for aluminum almost look like a compressed paper, but they cut very well. Plasma will work, but you don't have one I'm assuming. Torch won't work either. Jig or sawzall if you can reach the weld with them. Sorry for my /forums/images/graemlins/confused.gif