Restoring An Old Bumper: Metal Working Suggestions On Removing A Bar
 

I am restoring a Euro BMW 635 CSi front bumper with limited success. I would like to remove the rusty, heavy crash bar as indicated with the yellow arrows without damaging the surrounding thin gauge metal of the actual bumper.

I've tried my angle grinder and can only get about half way through then it bottoms out. I've tried my die grinder (same story) and I've also tried using a really small metal cut off wheel on my Dremel to cut the welds off with limited success.

If I heat it, it will warp the metal, so that's not an option. What other tool options are available?

Thanks and looking forward to reading your replies,
Yasin

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Since the bar is behind the bumper, is there a reason, why you want to remove it?

Its extremely heavy and rusting and would like to remove it so I can media blast the back side of the bumper and then powder coat or paint the back of the bumper. These bars were an '80s afterthought to Federalize the car and atrocious.

Its likely ( looking at the pix) that the bar was spot- through welded from the front and then chrome plated. I have a fair amount of experience with projects like this and I would leave it, have the chrome stripped ( acid dipped) that should take care or the rust, then you can finish it the way you want.

I really don't see a practical way to remove it.

First put the guard back on the grinder, if that wheel breaks up your fingers will thank you.

Get some more thin cut off discs and slice the tube lengthwise until you can grind from inside the tube.

You can also get some thinner cut off discs .040" or .045"

Here's your solution - just decide how much you want to spend to get it done. You'll probably want to pick up 1 or 2 different style blades - perhaps a full assortment.
If you don't already have an oscillating tool - you'll find lots of uses for it once you do!

http://forums.pelicanparts.com/uploa...1560041439.JPG

+1 for the oscillating tool. I have a Dewalt battery powered tool that has multiple uses. Should have bought one years ago.

Sorry for the hijack.

What is the diameter of the pipe you are trying to remove ? Is your angle grinder a 4 1/2 " ? I find it hard to believe that you can't cut the pipe out with it . You may have to do several long cuts then multiple cross cuts . I agree the pipe is probably spot welded to the bumper . I think the best you can hope for is to cut out about 75 percent of it the balance you will have to grind out .

The multi tool that others have suggested is a great tool , however in this application I think it would be painfully slow. The blades are generally only one inch wide so they take a very small bite .

Slit the pipe down the middle then open it up and see were it's welded. Drill out spot welds etc...

Ok guys, thanks for chiming in.

I decided to venture to Harbor Freight and bought the oscillating multi tool ($23) and then onto Home Depot and bought a good quality Bosch carbide cutter ($35).

Using my 4 1/2" angle grinder I made several rectangular (longitudinal) window cuts that way I could drive the angle grinder deeper into the bar (as it was bottoming out before) and I used the oscillating HF tool in the tight areas and also to break the spot welds. I took the bar out in sections and also used a bit of working the bar back and forth by hand to fatigue the welds.

By 9:15pm I was done and my T-shirt was soaked, the shower afterwards was welcomed.

Here it is removed:
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use a drill
 

Just drill a hundred holes in the bar than chisel it off, maybe two hundred - it's easy

Clearly you need a tall cup of coffee this morning

Good job man, persistence pays off!