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Do I buy a 5/16" or a 3/8" spot weld cutter to drill out the 5/16" spot welds on my 63 cowl? Objective is to reduce the damage while drilling them out and making weld holes smaller.....but would a 5/16" cut it out?

Thank you!
 

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Go as small as will loosen the weld. It is worth the cost to buy both sizes and only use the larger one if needed.

A recommendation is to carefully grind out the spot welds in complex and hard to get to areas like the cowl. You run the risk of drilling holes through lower panels that become very difficult to fill weld back together. This can get really creative in areas of the dash, cowl and firewall.
 

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should you inadvertantly drill all the way thru you can get copper strips and or plug weld pliers with copper that you can use as backings / heat sinks. You clamp then down, fill in the back hole with your welder, grind it level with the sheet metal. thn you can add the top sheetmetal.

examples:


 
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