"Grinding" down aluminum welds?

[Mike W]

What can I use to level an aluminum bead on a butt weld down to the parent metal level? This would be on large pieces of 1/16 aluminum. I have heard of an abrasive that is made for aluminum but have not seen one. Any ideas out there? Thanks.

[dseman]

If all you want to do is level the bead profile, then a sandpaper disc on an angle grinder will do. Norton and Pferd,as I'm sure others as well, make flap discs and grinding wheels for AL in addition to the sanding discs. Go to their sites and check them out. Portable band files like Milwaukee could also be used with a suitable abrasive. What you do after grinding the bead profile may determine the specific type of abrasive used. Ie- paint, re-weld, just make it purdy???
Non-wovens would be a good next step after removing the bead if you want to restore the polish a bit.

-dseman

[craig]

random orbit with about 80-120 grit. this will minimze any gouging into the parent metal. may take longer though.

[dseman]

Yes, and if someone is really cheap they can take a chisel, or maybe a hacksaw blade cutting perpendicular to the length of the bead as well! I would say if you are that cheap you shouldn't be working in metal, maybe stick with pvc or wood structures!

-dseman

[DaveD]

How about a carbide cutter mounted in a router to get most of it cut off? Groove the router's plastic base to straddle the weld and set the bit almost flush with the base

[dseman]

There are many ways to skin this cat. My last post was meant to be a joke. More needs to be specified from Mike as to what the intended quality of the 'grind' needs to be. As I've said before, the better the question, the better the answer.

-dseman

[Mike W]

I just want to end up with an almost invisible weld for looks. This is on a item where a bead would look out of place.

[dseman]

Is the non-weld metal polished,satin, brushed, or just oxidized? Each would require a different technique. I think you've got enough information that based upon what you want to do and the info available from the norton and pferd sites that you should be able to buy the sanding and non-woven products that you need. good luck.

-dseman

[Mike W]

It is anodized, sort of a gold color. I don't know what I will do about that except maybe paint it. It does not need to be an exact match. Or I could start a new hobby and get into anodizing. I heard that it is not that hard.