Suspension Pan question

Hi, I’ve got a question for you guys out there who have replaced their suspension pan. I’m trying to decide how to drill out the spot welds along the lower seam that runs lengthwise on both sides of the pan. If I use the spot weld cutter under the car, and from the outside of the car, I have clear access for the drill, but then I’m cutting holes in the panel that will remain with the car. That seems to be the way they did it in the European Car article, and they then plug welded through the holes left over. If you do it that way, why bother to use a spot weld cutter, I mean, who cares if you drill all the way through the panel that you are going to throw away?
The other way to do it would be to cut the welds by cutting through the old panel and trying not to go through the the other side, then drill holes through the new panel for plug welding. This seems like the logical way, but would require lots of cutting out of the old panel to gain a straight shot for the weld cutter.
Any opinions? I’d love to know how others have done it. I need to start cutting soon (maybe today if I get everything ready), so any advice is greatly appreciated.
Thanks Brad.

Brad:
Haven't done that, but have you tried to search past threads? Bet there are a bunch on that topic.

------------------
Marv Evans
'72 911E

I was in the same quandry you were about 3 months ago when I did mine. What I ended up doing was cutting thru the old pan as close to the seam as possible. I then, using an angle grinder, ground down the seam removing the remainders of the suspension pan that was spot welded to the seam. As I ground down the seam strips of the old pan between the spot welds would come loose, I would pull them off and grind the spot weld down smooth. Drilled holes in the seam on the new pan and spot welded it back in.

Kurt V
72 911E

Thanks Kurt, what did you use to cut the old pan? Jamie has a plasma cutter, but I'm not so lucky. Please don't say a hack saw...

I used an air chisel to get the big parts out and then used a dremel tool with a cutting wheel to cut next to the seam. I found that one cutting wheel will last for about 2 inches. Fortunately Walmart sold them in packs of 20 In hindsight I probably should have purchased an inline air shear from Harbor Freight for around $40. All together took me about 4-5 hours to cut the pan out, but what the hell I wasn't charging for my time!

Kurt V
72 911E

Kurt V knows how to do it. a nasty job. wear gloves if you like your knuckles, and eye protection.

Kurt V knows how to do it. a nasty job. wear gloves if you like your knuckles, and eye protection.

I rented a plasma cutter for a two day job unrelated to the 911 -- but, the price was very reaonsonable, transporting easy, and the labor saving incredible. Of course if I were to use a plasma cutter, I would have the gas tank far away from the car.