Operation CHARM: Car repair manuals for everyone.

Body and Frame - Spot Weld Cutter

REF. No. 58/29

TO: OUR MERCEDES-BENZ PASSENGER CAR DEALERS

DATE: January, 1985

SUBJECT:
SPOT-WELD CUTTER WITH REPLACEABLE CUTTER BIT

During accident repairs, a large number of spot welds may have to be separated. We recommend performing this work with the spot-weld cutter (tool no. 126 589 00 51 00).

Advantages:

1. The flange area for attaching new parts is not damaged.

2. The holes produced can be used as plug welding holes for the new parts.

3. Cutter bits are replaceable.

The service life of the cutter bit is optimized when the following precautions are adhered to:

1. Do not exceed a drill speed of 800 rpm.

2. At the the beginning of the milling process, run the drill slowly until the bit starts cutting.

3. Keep the bit teeth perpendicular to the work surface. Tilting the cutter will cause the teeth to break off.

4. Do not attempt to cut through welds produced by inert-shield (e.g. MIG, TIG) welding. These welds are very hard and will dull the bit in a short time. If possible, position the cutter bit so that it cuts around the hard weld spot.





Spot-weld cutter

Cutter Bit Replacement





An installation/removal tool (tool no. 126 589 01 51 00) is required for replacing the cutter bit (Figure 3).





1. With cutter in the drill, clamp the flat end of the installation/removal tool in a vise (Figure 4).





2. Press cutter onto the installation/removal tool (in direction of arrow) until the locking pin can be inserted through the holes in the cutter sleeve and pilot pin groove (Figure 5).





3. Slip worn cutter bit sideways out of its seat and install new bit (Figure 6).





4. Press cutter onto the installation/removal tool to relieve tension on locking pin, then pull pin out (Figure 7).





5. Slowly release pressure on the pilot pin until it is in the working position while simultaneously centering the cutter bit (Figure 8).





WARNING!
To prevent the cutter bit from becoming a dangerous projectile, never pull the locking pin out without applying counter pressure as shown in Figure 9. Apply pressure on cutter bit as shown in Figure 7.





Special Tool Information

NOTE:
Alternate spot-weld cutters available commercially, e.g. Blair, Model 11089 arbor and 11209 cutter (9 mm) with washer.