Can't believe I didn't think to just remove it all and save some cutting. I tried the center punch but must not have made enough of an indent to help. Thanks.If you are going to remove the front apron and the radiator support i wouldnt bother cutting them apart ,just take them out in one piece ,saves a little spot drilling .
Use a center punch in the middle of the spot weld ,the pin in the cutter will ride in the punch mark ,the deeper the punch mark the better. I dont use anything with the cutter because it gets in the joints of the metal and will cause problems when you try to primer and paint . Use a medium speed when cutting the spot welds to keep the heat down
The stuff where the cowl meets the window frame is the same color. Either it was also repaired long ago or it was like that from the factory as well.That is called brazing ,it was a repair someone did probably long ago ,you will find a few spots here and there ,like the tail panel ,at the bottoms of the window pillars ,and door post to rockers . This must be removed to mig weld .
The bottom of the radiator support is spot welded and welded ,the spot welds are larger than any where else and are a big pain in the butt to cut .
I'm considering just leaving the cross member in place especially since you mention the difficulty in removing it. It would at least save me the trouble of squaring up the new one. I just need to remove the remainder of the support from the cross member.When you get your radiator support ,get the one with the lower bracket already welded in place,its a big time saver,but only if you are replacing the front cross member also ,otherwise just get the radiator support by its self
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