Spot welds are commonly used to connect two flat panels of a car body together. On the early Mustangs, 1964 through 1968, the front and rear aprons were attached to the shock tower and the frame rail with spot welds. To replace one of the aprons, all spot welds must be removed to install a new panel. The most common inner fender apron that needs replacing is the front passenger apron. The battery is located along that apron and tends to destroy it over the years.
Tools Used: Spot weld cutter, Variable speed drill, Sharp metal chisel, SAE 3/8-inch drive and socket set, SAE wrenches, Wheel chocks, Safety glasses, Work gloves
Remove Spot Welds on a Fender Apron
Park the car on a hard, level surface. Set the emergency brake and chock the wheels.
Remove all of the components from the apron panel with the appropriately-sized sockets and wrenches. For the front passenger apron panel, disconnect the battery leads and the battery retainer then remove the battery. Remove the two bolts holding the starter solenoid in place and move the solenoid out of the way. Remove the bolts for the battery tray and remove it. Remove the fender bolts, then disconnect the headlight harness and remove the fender.
Locate the spot welds in the fender apron that need to be drilled out. There are welds vertically along the shock tower and radiator support, and horizontally along the front frame rail. There are also several on each end of the apron along the fender attachment line.
Use a good spot weld cutter. Do not be tempted to use a 3/8- or 1/2-inch regular drill bit. The secret to doing a good job is to drill only through the top panel while leaving the under panel intact. Using a regular drill will typically put a hole through the second panel before completely cutting the spot weld. Drill through the top section of all the spot welds on the apron.
Separate the two panels with a sharp chisel. Work carefully to avoid damaging the second panel. Once the panel is removed, the replacement panel can be installed.
Tips & Warnings
Always wear safety glasses and work gloves when working around sharp metal and drilling shards.
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