Grinding down welds on sheet metal

[pressbrake1]

I use the edge of a thin cut disc then roloc pads
If possible body file to finish.
If it’s a panel joint I gas weld as it’s soft then dress with dolly and final with body file

 

[brightspark]

its ok cleaning a bit of weld off with a 1.omm slitting disk at an angle. just sufficient to do it with hardly any flex. ok for getting rust of as well without digging in . never broke one yet doing it

 

[Pigeon_Droppings2]

Only time I've ever broken a disc was when I stood on one. If the disc is used at 90 degrees then it's no different to cutting with it if you are running it along the welds.

...but I guess there will be a temptation to use it like a flap wheel!

 

[droopsnoot]

Like everyone else, I tend to pick depending on the location and access. I've used the edge of 75mm cut-off discs in my air cut-off tool, and bigger ones in the proper angle grinder. Also flap discs and carbide burrs where necessary, even carbide burrs and cut-off discs in a Dremal-a-like when I've really got plenty of time and not much access for anything bigger. I bought a cut-off disc adapter for my mains die grinder, but it has no shield and the speed is not adjustable, so I don't really like using it much - it usually has the carbide burrs in it. And, as above, I try to do the weld from the side that's either hidden, or easiest to access to grind down.

I'd love to be able to weld without getting so much build-up in the first place, but that seems to happen sometimes and not others.

 

[Exuptoy]

I think the welding procedure is the key. Let in a panel repair using Fitzee Fabrications technique at 45 degrees then spot welds at various places to keep heat soak low then black n decker power file and maybe sanding discs on a backing pad on a 4.5inch grinder. Literally no distortion.

 

[Little Jerry]

Appreciate all the responses guys - many ways to skin a cat...

Those black and decker power files look interesting as a way to lessen the area being grinded and not too expensive - i'll have to pick one up.

 

[Pigeon_Droppings2]

Definitely...it's the tool I use the most I think. Good for cleaning before welding too as they are very precise plus a lot less noise than a grinder.

Top tip which I learned on here is to buy the wide belt sander belts...make a small cut with a knife (just to break the surface)...then you can tear a belt off for the finger file....as easy as it sounds as they have a grain to them.

Just don't buy the evolution file....I did that as an "upgrade"....it was rubbish!

 

[Little Jerry]

what grit you using on the finger file when you getting the weld flush?

 

[Craig-SM]

Definitely...it's the tool I use the most I think. Good for cleaning before welding too as they are very precise plus a lot less noise than a grinder.

Top tip which I learned on here is to buy the wide belt sander belts...make a small cut with a knife (just to break the surface)...then you can tear a belt off for the finger file....as easy as it sounds as they have a grain to them.

Just don't buy the evolution file....I did that as an "upgrade"....it was rubbish!

What belt sander are you using as I was looking at the Evolution but seeing your post and another on failed bearings, it may no longer be wise.

 

[Pigeon_Droppings2]

Black and Decker KA900E is the only one I buy...when they're on sale you can pick them up for £30.

The evolution was junk....not just the bearing issue but it also spat belts across the room constantly. It was all show and no go....the black and decker looks like you'd break it in 10 minutes....my first one lasted years and like a fool I gave it away (still working). I'm on my second one in about 8 years....so they last well if you look at what they go though.

Blue zircon belts are the ones for steel....the brown ones are no good...maybe for woodwork but not steel.

 

[Cobbler]

I went into Lidl’s the other day & they had 3” sander belts reduced to £1.50 for 6. I bought a pack & split them down to fit the power file. Probably won’t last long, but at that price they don’t need to.

 

[Little Jerry]

Bought the black and decker finger sander - only $87 AUD with free shipping from UK on amazon - nice and cheap compared to most of the other tools I've been buying recently.

 

[Little Jerry]

Bought a hand air sander as well to suit roloc discs so I will try out all the options...

 

[Craig-SM]

Black and Decker KA900E is the only one I buy...when they're on sale you can pick them up for £30.

The evolution was junk....not just the bearing issue but it also spat belts across the room constantly. It was all show and no go....the black and decker looks like you'd break it in 10 minutes....my first one lasted years and like a fool I gave it away (still working). I'm on my second one in about 8 years....so they last well if you look at what they go though.

Blue zircon belts are the ones for steel....the brown ones are no good...maybe for woodwork but not steel.

Cheers, I'll get one ordered.

The specs show it's a 451mm belt but does it have enough adjustment for a standard 457mm belt?

 

[Pigeon_Droppings2]

Think 457mm are the ones I use. I bulk buy on eBay....very easy to tear and the blue ones are excellent on steel.

Just double checked...I'm using 75x457 zirconia. If you bulk buy they are cheaper...I just use a knife to make a 10mm slit...then tear the belt...work round both directions to the glue join....then just tear thro by holding both sides of the join.

 

[awemawson]

Has anyone come across a suitable case for the B&D KA800e power file ? I find that if tools like this lay about loose they soon deteriorate and anyway it makes storage so much easier.

I was surprised that none of the sellers I found offered cases

 

[brightspark]

Only time I've ever broken a disc was when I stood on one. If the disc is used at 90 degrees then it's no different to cutting with it if you are running it along the welds.

...but I guess there will be a temptation to use it like a flap wheel!

I broke one last nite grinder was on the floor late on and it was dark in garage put my foot down and heard a noise sure enough I knew without looking you recognise the sound of disks smashing was brand new as well 40 pence wasted there

 

[droopsnoot]

Has anyone come across a suitable case for the B&D KA800e power file ? I find that if tools like this lay about loose they soon deteriorate and anyway it makes storage so much easier.

I use an old four-drawer wooden filing cabinet that was being thrown away - electric drills in the top, grinders next down, router and jigsaw below that, and general "stuff" in the bottom drawer. Not all that portable, I grant you.

I'll be keeping an eye out for this power file, sounds like a useful thing to have.

 

[Pigeon_Droppings2]

Mine is stored on my floor-drobe most of the time

 

[Little Jerry]

Hey pigeon

What grits are you using the most on the power file? I was thinking 80 / 120 is probably a good start for levelling welds