Accurate metal cutting

[PigFilth]

In the past I have used a grinder to cut out rusty metal prior to welding in new - I've found the thing very unwieldy and unsuitable for small sections due to the size of the disc. I was thinking of trying a Dremel type of arrangement for more intricate (small) repairs - as I don't have a compressor.

Just wondering what most people use to do this on bodywork - a plasma cutter is well out of budget and I don't particularly want to buy a compressor as I have no other use for one really.

[OldSkoolRS]

I've got to trim the inner wing of my RS2000 to fit a repair section, having roughly cut the rusty pieces away I was planning on using my new Dremel to do the accurate trimming. I did consider a jigsaw but find that these can be hard to control as the outside edge is unsupported and tend to flap up and down with the jigsaw. I'll let you know how I get on, but I'll be interested in any other suggestions.

The pic I've shown shows where I need to cut (the top plate is now removed so it's the middle section I need to cut before letting in the repair section, then refit the top plate (which is amazingly rust free).

EDIT: Just to add that I bought a pack of 12 quick-click Dremel metal cutting discs for about £15 from B&Q. Maybe not the cheapest place, but at just over a pound a disc even if I use the whole pack doing this job it's not a major expense (the repair panels were much more, but far cheaper than an entire inner wing, which isn't really necessary anyway).

Edited by OldSkoolRS on Sunday 10th April 20:10

[PigFilth]

Cheers - would definitely be interested in following your progress. My need is to re-do a repair on the floor - I did the passenger side with a grinder but it's not as neat as I would like. I have a Dremel-type drill (though it's not a Dremel) - did you use the flexible attachment or just a disc on the machine? Mine doesn't have the attachment so I'm thinking of buying a genuine Dremel.

[BliarOut]

Metal shears are pretty good for accurate cutting.

[sunbeam alpine]

One thing to bear in mind is that Dremels use a lot of cutting discs if you start using them for bodywork. The results are good, but if you catch the disc on something it flies to bits. I've just picked up a cheap second hand plasma cutter. Works a treat.

[cptsideways]

Try some slimline cutting discs, good ones not cheap ones, they need to be the 1.5mm type

[PigFilth]

In my case, it's not just the thickness of the disc that matters - the large diameter of the grinder discs is the issue when cutting small pieces.

[OldSkoolRS]

I haven't used the Dremel in that picture; that was done with a standard metal cutting disc in my angle grinder and a spot weld cutter as needed.

I bought the Dremel 4000 kit from Amazon (£99) which has a number of accesories including the 'quick fit' cutting discs which I used to trim the outter wing off at the front edge, hence buying some more from B&Q. The plan is to cut where I've drawn the white line using the Dremel itself, not the flexible attachment (though I may give that a try incase it's easier).

I've got more resto pictures over on Rallye Sport Escorts forum, but it's a slow job that I pick up fro time to time as I feel in the mood. It's weird, but the rust stops about 2 inches under the top plate, so at least I can hide the seam welded new joint mostly under the top plate.

[PigFilth]

Forgot all about the RS Escorts forum - I'll have a look on there.