If you are reading this article, you will probably be a fan of welding and manipulating metal to make structures, components, and hobbyist inspired art. Metal is such a key material in all walks of life, and the best spot weld cutters are part of that process.
We show you the 5 best spot weld cutters money can buy.
- M2 quality steel
- “Skip-proof” pilot
- Comes with spare pilot
- Double-sided
- Universal kit
- Ideal for automobile repairs
- Comes with 10 spare cutters
- Spring-loaded arbor
- Ideal for most sheet material
- Made of cobalt steel
- Non-slip titanium-tipped
- High heat resistance
- Veteran-owned company
- Robust plastic container
- universal 0.25-inch fit
Review Methodology: At Sensible Digs, we take a rigorous approach to evaluating the best spot weld cutters. We analyze each product from a user’s perspective, using a variety of criteria and quantitative measurements to assess performance. Our hands-on experience and professional expertise in the field allow us to identify key decision-making factors, such as durability, ease of use, and efficiency. We then rank each product based on these factors, providing an in-depth review and score. We also delve into the design choices made by each manufacturer, explaining how these affect the user experience. Furthermore, we compare each product to its competitors, highlighting what sets it apart. Our results are backed by factual data and thorough research, offering you reliable, objective information to help you make an informed decision. Trust that our recommendations are based on solid evidence and substantial findings.
The Best Spot Weld Cutters of 2024
Given the vast choice of spot weld cutters, choosing the best 5 was a challenge. Here are our favorites.
Blair 11096 Cutter Set
Best Professional Spot Weld Cutter
Very few spot weld cutters can compare with the Blair cutter set. It is the best choice for professionals. This set is highly popular and comes with three 0.375-inch cutters, as well as a “skip-proof” arbor pilot and a spare pilot should you need it.
The blades are double-ended, which means they cut more efficiently, putting less strain on the cutting blades and preserving the life of the cutter. When the bottom teeth dull, simply switch the cutter over and use the second set of teeth.
This set fits 0.50-inch hand drill chucks, so they are pretty much universal, and they are manufactured from high-grade M2 steel, meaning they hold their sharpness for longer.
Pros
- M2 quality steel.
- Popular with professionals.
- “Skip-proof” pilot.
- Spare pilot.
Cons
- Expensive.
Product Specs
| Weight | 1.6 ounces |
| Dimensions (inches) | 8 x 6 x 1.5 |
| Number of spare cutters | 3 |
| Material | M2 steel |
| Sizes | 0.375 inches |
| Price | $$$ |
Our Ratings
User Experience
Handbook Spot Weld Cutter Set
Best Universal Spot Weld Cutter
This is the best universal cutter set because it has a spot weld cutter, a sheet metal hole cutter, and a punch remover panel separator. It is the ideal toolset to get when you are working on that classic car.
The high quality, double-sided blades are made from heat-resistant steel to offer minimum distortion thanks to the sharper cutting edge. The blades are 0.375 inches in size, which seems pretty standard for spot welds, and because it comes with 5 blades, you never need to worry about the cutters dulling.
Plus, because the cutters are double-sided, all you need to do is flip them when they start to lose performance, and you are ready to go again.
Pros
- Double-sided.
- Universal kit.
- Ideal for automobile repairs.
- 5 blades.
Cons
- Teeth prone to snapping.
Product Specs
| Weight | 7.1 ounces |
| Dimensions (inches) | 3.9 x 3.7 x 1.1 |
| Number of spare cutters | 5 |
| Material | Steel |
| Sizes | 0.375 inches |
| Price | $$ |
Our Ratings
Personal Perspective
EEEKit Rotary Spot Weld Cutter Set
Best Spot Weld Cutter for Beginners
When you are new to something, you want to be sure that you are using the best tools for the job and it won’t break the bank. This high-speed steel cutting set has 10 spare cutting heads. That means you can keep cutting without spending more on replacement heads.
They are also double-sided, so you actually get 20 spare cutting surfaces, plus the one that comes attached to the arbor. It also has two additional pilot pins, and the bit is spring-loaded to make it easier to control the cutter to find the center-point of the spot weld.
This ensures the maximum removal of material and leaves a burr-free surface. This set is ideal for steel, aluminum and iron sheets, as well as fibre-reinforced plastic (FRP), making them the ideal tool for a beginner.
Pros
- 10 spare cutters.
- Spring-loaded arbor.
- Ideal for most sheet material.
- Perfect for beginners.
Cons
- Cutters dull quickly.
- Feels cheaply made.
Product Specs
| Weight | 2.2 ounces |
| Dimensions (inches) | 6 x 1 x 1 |
| Number of spare cutters | 10 |
| Material | High-speed steel |
| Sizes | 0.375 inches |
| Price | $$ |
Our Ratings
Community Feedback
ABN Spot Weld Cutter Drill Bit Set
Best Heat Resistant Spot Weld Cutter
If you want a spot weld cutter with maximum heat resistance, look no further than this 3-piece cobalt and titanium-tipped set. Thanks to the high heat resistance of the cobalt and titanium, these drill bits will weather the punishment better and last longer.
It has three size variations, ranging from 0.25 inches, 0.313 inches and 0.375 inches, so it has most spot weld sizes covered. There is no need to use a pilot bit thanks to the non-slip specially designed centering nib that grips the spot weld and holds it in place.
This set also has a 1-year warranty against defects as a result of manufacturing quality rather than misuse.
Pros
- 1-year warranty.
- Cobalt steel.
- Titanium-tipped.
- High heat resistance.
- Non-slip tip.
Cons
- Lacks a cutter.
- Takes longer.
Product Specs
| Weight | 1.76 ounces |
| Dimensions (inches) | 3.9 x 3.25 x 1.2 |
| Number of spare cutters | N/A |
| Material | Cobalt steel and titanium |
| Sizes | 0.25 inches, 0.313 inches and 0.375 inches |
| Price | $$ |
Our Ratings
First-Hand Impression
KCC Industries Spot Weld Cutter Set
Best Budget Spot Weld Cutter
Considering this set is a KCC brand, it is incredible value for money. It comes with two arbors and four double-sided cutting blades. It also boasts high-quality heat-resistant steel cutters, protecting the cutting blades for maximum usage.
KCC is a veteran-owned business, so not only are you getting a great product, you are doing your bit for our brave men and women. It has a universal 0.25-inch fit for drill chucks, and the cutters measure 0.375 inches, fitting the standard spot weld.
Everything comes packaged in a durable tube for safe storage and easy transport.
Pros
- Veteran-owned company.
- Good value for money.
- Robust plastic container.
- High-heat resistance.
Cons
- Teeth snap easily.
- Dull quickly.
Product Specs
| Weight | 1.58 ounces |
| Dimensions (inches) | 3.19 x 0.79 x 0.31 |
| Number of spare cutters | 3 |
| Material | High-speed steel |
| Sizes | 0.375 inches |
| Price | $ |
Our Ratings
User Experience
| Product | Best | Weight | Dimensions | No. of spare cutters | Material | Sizes |
|---|---|---|---|---|---|---|
| Blair 11096 Cutter Set | Professional | 1.6 oz | 8 x 6 x 1.5″ | 3 | M2 steel | 0.375″ |
| Handbook Spot Weld Cutter Set | Universal | 7.1 oz | 3.9 x 3.7 x 1.1″ | 5 | Steel | 0.375″ |
| EEEKit Rotary Spot Weld Cutter Set | Beginners | 2.2 oz | 6 x 1 x 1″ | 10 | High-speed steel | 0.375″ |
| ABN Spot Weld Cutter Drill Bit Set | Heat Resistant | 1.76 oz | 3.9 x 3.25 x 1.2″ | N/A | Cobalt steel & titanium | 0.25″, 0.313″, 0.375″ |
| KCC Industries Spot Weld Cutter Set | Budget Pick | 1.58 oz | 3.19 x 0.79 x 0.31″ | 3 | High-speed steel | 0.375″ |
What Is a Spot Weld Cutter?
A spot welder is a tool that transfers heat through copper alloy electrodes to weld two or more sheets of metal without the use of additional filler. The heat comes from an electrical current.
Spot weld cutters are specifically designed to remove those spot welds without using a rotary cutter, making the job neater, faster and easier.
Spot welding is one of the oldest welding methods, and it works best with thin sheet material, which is why you see it commonly used in the automotive manufacturing industry. It is also an ideal method of making temporary welds.
How To Choose the Best Spot Weld Cutter
It is a challenge defining what makes the best spot weld cutter in one word. Several factors are at play here, but there are some basics you should consider.
Brand
There are several brands of spot welder cutters, and they all claim to be the best. Some are more popular, with higher customer satisfaction and sales figures. This translates into a higher price tag for the very best.
The brands to look out for are Blair, KCC and Grizzly, to name a few.
How Many Cutting Blades?
The amount of cutting blades you get with your spot weld cutter matters. Most brands offer a choice of two blades as part of their package, but if you need to widen your choice, make sure that you can purchase additional blades separately. If not, this will severely restrict the versatility of the tool.
You also need to know that these spares are affordable and won’t break the bank.
Quality of the Materials
The materials used in the spot weld cutter’s manufacture make a massive difference in how it performs and its longevity. Blair weld guns use M2 steel, which is durable and hard-wearing, while KCC also offers high-quality steel in their manufacturing process.
The quality of the components is vital if you want a spot weld cutter that lasts decades instead of a couple of years.
Price
Price could be first, middle and last on the list. It all boils down to the budget. How much do you want to spend on your spot weld cutter? The truth is, you get what you pay for. The quality of the materials used, the warranty and the tool’s capabilities are all affected by the budget.
Warranty
Warranties translate into peace of mind. The longer the guarantee the spot welder has, the less the machine ages, and the longer you get to use it hassle-free. Check each brand for its warranty, as it will vary enormously between them.
Always try and get the best warranty you can.
How To Use a Spot Weld Cutter
Locate the spot welds you want to remove, and using a drill and small bit, drill a pilot hole in the center of the spot weld. Sweep away any strands of metal. Insert your weld cutter into the same drill, and using the pilot hole as a template, drill down until the teeth have ground away from the weld material.
Some kits have centering tips included to make neater and more accurate cuts. The best cutters will leave the spot weld smooth and burr-free.
Spot Weld Cutter FAQs
What Is Squeeze Time in Spot Welding?
Squeeze time is the interval between the electrode’s initial application on the material and when the current is applied. Squeeze time is necessary because it delays the current until the force of the electrode has reached the correct level.
How Far Apart Should Spot Welds Be?
The recommendation is that the spot welds should be at a distance equalling 10 times the material thickness. This helps to attain adequate joint strength and to take account of any overlaps of the sheet material.
What Is the Best Way To Remove Spot Welds?
The best way to get rid of spot welds is to use a spot weld cutter. With a drill and a pilot bit, you find the center of the spot weld and drill through. Then, with the cutter tool, you can easily remove the excess weld material, leaving it burr-free and smooth.
How Do You Drill Through a Spot Weld?
Using a drill and a set of drill bits is an easy way to drill through the spot weld. However, it can punish the bits and wear them down somewhat. The easiest way is to start with a small bit as the pilot and graduate to a larger size, using the pilot hole to centralize the bit.
It might take longer to do it this way, but it is cheap and easy to do.
Can I Spot Weld With a MIG Welder?
You can spot weld with a MIG welder, but you must first purchase a dedicated torch nozzle and a pair of locking clamps. You also need two drill bits. You can buy a complete kit for this very purpose.
Line up the panels and measure where you want the weld to be. Mark the spot and separate the panels. Using the drill bit, drill the hole through the top panel. You now have the recess where the weld can sit. Realign the panels and measure the next spot and so on.
Repeat this process until you are ready to weld. Use the clamp set and hold them in place, positioning the torch nozzle over the spot. It’s now time to start spot welding.
What Size Should Spot Welds Be?
The diameter of spot welds typically ranges from ⅛” to ½.” The exact number depends on the thickness of the material you’re working with.
If you’re working with limited weld space, experts suggest using one large weld instead of several smaller ones. That large weld will help create a stronger bond.
How Thick Can You Spot Weld?
Spot welding is a technique used for parts no thicker than 3mm. The diameter of a spot weld ranges from 3 to 12.5 mm, but these numbers are not set in stone.
Certain variables influence the thickness of a spot weld. Keep in mind that it’s best to go with a ratio of a maximum of 3:1 when spot welding if you want to achieve the best results.
Can You Remove Spot Welds?
There are several methods for removing spot welds, but you first have to identify the size of the welds and the material welded.
You can use a drill and chisel, a standard technique for eliminating spot welds. Just you bore a hole through its center and break the weld apart with a chisel. This simple and fast technique makes it ideal for spot welding on smaller objects.
Another method is straight-up cutting. You need a spot weld cutting tool to make a circle cut around the weld you want to remove.
You can always grind the spot weld to remove it, too. But you only grind the top metal layer of the weld, preventing any damage to the bottom side of the weld.
Is Spot Welding Better Than Soldering?
Spot welding is typically regarded as being better compared to soldering because it’s cheaper and less time-consuming. When you spot weld, the connection generates less heat but offers a secure bond.
Soldering implies using a melted alloy to join two parts, but you are not melting the metals you want to join. That makes spot welding a more secure option, especially when you have to weld structures.
Soldering is better when working on more minor welds, such as electrical circuit boards or plumbing pipes.
As opposed to welding, soldering doesn’t require as much experience, so it’s the better choice if you are a DIYer.
What Is the Best Spot Weld Cutter?
The Miller Blair – Spotweld Cutter Set has gained popularity amongst professionals for its quality and durability.
Crafted from quality materials, the set is designed to last for multiple welding jobs and even comes with a spare plot for added value.
The set’s sharpened blades make it ideal for cutting rust and tough metal quickly and cleanly, getting work done faster than ever before. With this spot weld cutter, professionals know they are working with quality materials that will always get the job done right.
A Cut Above the Rest
If you are working on a car or restoring a classic, sometimes you need to make light work of spot welds to remove rusty panels. A spot weld cutter does this and also stops you from butchering the panel by trying to pull it apart, causing unnecessary damage to your project.
Get a spot weld cutter and make your life easier. It could be one of the best investments you make.
