I need a tool to cut off my rusted quarters and I have some small spots (look like bullet holes honestly) on the doors that need to be cut out too. I have no idea what I should use. I've heard of using a cutting torch but I don't cut metal often enough to justify buying one. Is there something I can buy to use with a common power tool most people would have?
Thinnest cutting wheels(abrasive) you can find for a 4.5" grinder or airtool. If you can spot sand blast the area, you can see where the rust actually has punched through or thinned the metal that you can miss just by looking.
Avaiton hand snips work well for cutting a single layer of sheet metal. For your door holes start in the hole and cut out a circle around it. They will also work well to cut the repair piece. Pick up a left and right set. Mitch
I just use an electric die grinder with a thin cutoff wheel. Way easier than cutting with an angle grinder, because the wheel is perpendicular to the tool, so you can see your cuts. Like this, but with a cutoff wheel instead of a grinding wheel.
I use aviation snips, cut off wheels, and my personal favorite the air saw. I got it on sale at harbor freight for $10 and it works amazing for the price. http://www.harborfreight.com/high-speed-metal-saw-91753.html
Harbor freight air saw here to for close work where you have plenty of room behind the area your cutting. For harder areas, I use a diegrinder with a cutoff wheel.
Air saw. cut-off wheel, nibbler or plasma cutter - never a torch if you want a straight panel when you are done.
I've got the electric version, I was pretty impressed with it as well. Used it to cut the hole in my hood. I hate doing circles with a die grinder
I got one of these a couple months ago http://www.harborfreight.com/air-tools/specialty-air-tools/3-inch-high-speed-air-cutter-47077.html but everytime I touch it to metal it slows down to a crawl and then to a complete stop in about three seconds. Any advice? I've tried upping the psi but that doesn't help at all. That's why I'm looking for an alternative but if I can get that to work.