Whats the best and easiest way to remove spot welds. I tried using a hammer and chisel but it was not going to well.

 

drill them out.... 5/16 bit

or use an air chisel if you know what you're doing.... this will obviously just tear stuff up... but if you're not concerned with saving the panel... you're fine

 

If the outer panel is being discarded, you can use a 3" cutoff wheel about 1/16 thk as a grinder. I have tried a couple different spot weld cutters and they and I didn't play nice together. I'm sure it was operator error, but it seemed I would wind up cutting thru too far, and the lower panel that I wanted to reuse would require repair before installing the new panel on top of it. Here's a picture that shows the cutoff wheel used to grind out the spot welds. IMO, you have a better, less obstructed view of the spot weld to see what you're doing, and I'll grind the metal back and forth across the spot weld until you start to see the top layer turn blue. This is a heat indicator, which also indicates the metal is getting thin. (my clue to slow down) When you start to see shiny metal again, you are now in the second layer, so just move around a bit to insure you got all of the spot weld and gently pry apart.






If you are saving the top layer, and need to remove and discard the bottom layer, just drill through with a drill bit the same size you use for plug welds. The drilled hole releases the spot weld and drills your plug weld hole all in one step.

 

get a spot weld bit for a drill and go MED. speed with it or you will burn up the bit. but they can be pricey. so hit it with a drill bit and hammer and chisel to split the pannels

 

Thanks guys for all the help but I went by using a regular drill bit to remove them. Heres a link to some pictures.
https://honda-tech.com/forums/appearance-build-threads-122/ef-project-2585495/

 

i always use spot weld drills.. but you can use a cut off wheel as well.. although i wouldnt if you plan on reusing whatever it is you're taking the spot welds off of..