What tool to cut out floor pans?

b0517 said:
Thanks for all the replies. I'm looking for what will make the cleanest cut, the amount of time it takes does not matter. Thanks again.

Sawzall hands down. The cutting torch is messy, the angle grinder is LOUD and slow and not a very clean cut. (all just my opinion of course) Plus as was already sid, the sawzall can be used for about a billion things. I think its just about my favorite tool in the garage :D
 
I've tried 'em all and the plasma cutter whups a$$ on everything. However, I do this stuff very frequently and for a living, so that justified the grand for the cutter (you also must have an air compressor).

So, a wealthy Santa aside, I've had great luck with a nibbler (if you have an air compressor, or maybe there are electric ones) that I got at Harbor Freight for like $20. It makes a mess with the billion little crescents it nibbles away, but so what.

My 12 Amp Hitachi sawzall is a beast as well, and as others have said, you'll use it for all kinds of stuff besides your car.

A good angle grinder with a slitter disc works well, but it's hard to get a nice straight line. It's also very useful for other stuff though.

Good luck!
 
Plasma cutter is best but costly. Die grinder good but it takes time, throws sparks, cutting wheels fracture easy, and most of all hard to go around corners. Saws-all also good but may be a little bulky when you get to the front floorboard under the dash. MY suggestion would be a body saw which is like a miniature sawsall except its made for cutting body panels, you can cut faster than a die grinder, very easy to control and goes around corners well. They are about the size of a nibbler (Which doesnt go around corners well either). If you have a compressor then that would be the best thing and they use very little cfm so even a small compressor will work. Just be sure to get under the car and remove your fuel line so you dont saw thru it. Youll need a die grinder or something else when you get to the frame rails up front and youll need to cut some spot welds there too. Good Luck.
 
It sound like tha Plasma Cutter is the way to go, but how hard is one to use. I figure I could rent one for a weekend if I could do the job myself. For those of you that have used the Plasma Cutter how do they do around corners? Thanks again for all of your help.
 
Plasma cutter

I have a Plasma Cutter and it works GREAT. It cuts exactly where your hand goes. Could be good or bad. My hand isn't as steady as I thought it was. Cuts are kinda "wobbly" so I use a straight edge sometimes. But it cuts like nothing else.

Dave