Or a farrier's rasp?
I’m pretty sure there are purpose made bodywork files for this exact thing, you’d just need a very coarse one. Maybe a panel beater will chip in.
A Dreadnought file works nicely, that amount of alloy would keep you fit.
Something like this might work for you, I've seen them fitted with some very aggressive files.
Zoro prices do not reflect real prices. The price I’ve had was about half that.
Yes they eat aluminium. That holder is for curved surfaces and you adjust it to bend the file. Bend too much and it shatters...
I made a fixed holder to get it rigid and a smaller one for the shattered one Great for deburring.
I usually use the body files for fine tuning. but starts with flap discs. The Norton Quantum discs do really good on aluminium
Can be quite brutal with them and even if they get a silver look they still eat good.
If you're only taking the top off the welds the file would probably be a good alternative though.
Serious tool envy, that’s lovely, woof woof!
I have a fairly heavy but hand held belt sander that I have used with a coarse belt for longish runs of alu weld that needed to be flush. Makes short work compared to anything else I tried.
Separate names with a comma.