Hi Honda-Tech'ers,

my arm injury has made it challenging to weld consistent-uniform-looking "stack of dimes" 4043 welds on aluminum intercooler pipe. Structurally, the TIG weld has good penetration and fusion, but it's just not aesthetically pleasing. Are there any grinding tools or methods that have worked well for you folks on aluminum pipe welds? I'm not looking to grind the weld flush with the pipe, just enough so it looks like a uniform flat ring slightly above the pipe.

 

The only thing i have ever used was an angle grinder. You could probably use like a dremal or something but that might take awhile lol.

 

Thanks for your prompt reply Dioxine. Which grinding disc/wheel did you find worked best with your angle grinder and aluminum pipe welds?

 

Any time I have to grind, sand, or use high speed carbide tools on non-ferrous metals I use a wax based lubricant. This makes your tool not gum up. I'd start with like a 36 grit sanding disk on a 90 degree air tool to hog it off. The work up in grit size to get a good finish. Then polish it off with a blue scotch-brite.

Here's a link to some lube I use, it literally cuts your grinding time in half for aluminum.

http://www.wttool.com/index/page/pro...ting+Stick+Wax

 

There are some flap wheels available specifically for aluminum grinding, i think norton and 3m make some

 

I use a dynafile. Worked great.

 

Flap wheels on an angle grinder work great.

 

3M Roloc disk on a die grinder