Topic: Trigger Happy with the Flap Disc

[Ellz10]

Got a little trigger happy with the flap disc when I was cutting off tabs and triangles. Now about half of the spots I cut and grinded down are very wavy and uneven. Will post a decent picture tomorrow.

What is the best way to go about smoothing them down and rounding them out or blending it in? Metal file then sand?

Thoughts, input, advice. All is welcome.

[Kevnz]

Maybe a bit of braze? Or even body solder?

[Ellz10]

I meant flap disc. It was late when I posted this and I was exhausted.

[BomberMann650]

A long narrow strip of sandpaper can help restore roundness.  A file is good for smoothening too.

Someone actually made a tool attachment to motorize the process.  Basically a three wheeled belt sander with a spring loaded capstain.

[Ellz10]

A long narrow strip of sandpaper can help restore roundness.  A file is good for smoothening too.

Someone actually made a tool attachment to motorize the process.  Basically a three wheeled belt sander with a spring loaded capstain.

I'll go ahead and give the sanding a try first then.

I'd love to have that tool! I saw one sort of like it in the Eastwood magazine.


P.S.   That's a great avatar! 

[Ellz10]

Update*

I have not been able to restore the roundness of the tube frame. I don't know what to do at this point. Do I smother JB Steel stick on the spots and then try to shape it, I just don't know.

If I just take it to be powdercoated, can I just tell them there's wavy spots and to go heavier in those areas? Is there such a thing as buildable or self-leveling powdercoat kinda like there is for primer?
.I'm at a loss here and it's put a stop on my build.

[WhyNot2]

Update*

I have not been able to restore the roundness of the tube frame. I don't know what to do at this point. Do I smother JB Steel stick on the spots and then try to shape it, I just don't know.

If I just take it to be powdercoated, can I just tell them there's wavy spots and to go heavier in those areas? Is there such a thing as buildable or self-leveling powdercoat kinda like there is for primer?
.I'm at a loss here and it's put a stop on my build.

Wow, looks like a frame I'm working on. Mine just not quite that bad. I'm wondering what  to do too.

The places that will be hidden by the tank or othe things, I ain't gonna worry about those areas. Places exposed, maybe bondo, not sure, gonna give it a try.

[newday777]

I don't think jb weld will hold up to the heat cure of powder coating.
Better would be welding or brazing.

[newday777]

Besides the frame at the shock mount looks weak (holes?) besides being thin and not round.
Or get a donor frame and cut and paste.....

[BomberMann650]

There's always textured powder coat options.  That will blend the entire frame into a hand hammered look.

Would be unique for sure.

[ThePwninator]

Have you tried to file it out and then sand?

[Don R]

  Dude, you gotta stop doing that. There's no magic fix for that. Sorry.

[Ellz10]

Update*

I have not been able to restore the roundness of the tube frame. I don't know what to do at this point. Do I smother JB Steel stick on the spots and then try to shape it, I just don't know.

If I just take it to be powdercoated, can I just tell them there's wavy spots and to go heavier in those areas? Is there such a thing as buildable or self-leveling powdercoat kinda like there is for primer?
.I'm at a loss here and it's put a stop on my build.

Wow, looks like a frame I'm working on. Mine just not quite that bad. I'm wondering what  to do too.

The places that will be hidden by the tank or othe things, I ain't gonna worry about those areas. Places exposed, maybe bondo, not sure, gonna give it a try.

If the frame wasn't going to be powdercoated then I would try bondo.

Besides the frame at the shock mount looks weak (holes?) besides being thin and not round.
Or get a donor frame and cut and paste.....

I didn't do the best job of welding, but I had it redone by my brother and everything looks right now, the way it should.

There's always textured powder coat options.  That will blend the entire frame into a hand hammered look.

Would be unique for sure.

I'm going to write this down for later. Definitely would like to see my options and what it could possibly look like. Thanks!

Have you tried to file it out and then sand?

I have and the waves just won't round themselves out unfortunately.

  Dude, you gotta stop doing that. There's no magic fix for that. Sorry.

Ugh, I know Don, I'm trying! Haha, when my brother came over to help fix the gussets he said he'd come back next week and I think he's going to just pool weld then help me sand down those top rails so they're straight and even. He's a welder out in Wyoming.

[WhyNot2]

So, did you come up with a solution?

Lets see some pics?

Still working on mine, just spraying it down with paint remover, then gently grinding off the things I don't won't.

[Ellz10]

So, did you come up with a solution?

Lets see some pics?

Still working on mine, just spraying it down with paint remover, then gently grinding off the things I don't won't.

I did! My brother is going to come over next week before he goes back home to Wyoming and I believe weld a pool at the wavy spots then help me sand/file down properly so it's nice and straight and even! I'll post some pics of the during and finished result! Wish us luck!

[calj737]

Your brother (and you) would be well served to use Silicon Bronze filler to build up those thinned areas. It takes less heat to melt, is softer to sand smooth, and will take powder coat. The downside potential of using steel filler is you compromise the wall thickness due to internal rust as you try to weld and end up with a bigger mess than you started with. Plus, you’re heating the tubing in small areas and changing the strength of the tube in particular spots, not evenly.

A 3/32 filler wire and a TIG torch work a treat. Won’t need much more than 45 amps to do the job properly. (The tubing is only 0.063 wall thickness anyway).

[Ellz10]

Your brother (and you) would be well served to use Silicon Bronze filler to build up those thinned areas. It takes less heat to melt, is softer to sand smooth, and will take powder coat. The downside potential of using steel filler is you compromise the wall thickness due to internal rust as you try to weld and end up with a bigger mess than you started with. Plus, you’re heating the tubing in small areas and changing the strength of the tube in particular spots, not evenly.

A 3/32 filler wire and a TIG torch work a treat. Won’t need much more than 45 amps to do the job properly. (The tubing is only 0.063 wall thickness anyway).

He hasn't been welding nearly as long as you, nor as well I would imagine, but he's been at his job for 7 years so I would hope he's decent enough but I will definitely show him what you said so he can use it exactly. Thanks Cal!

[Trevor from Warragul]

JB Weld can be powder coated.

[WhyNot2]

JB Weld can be powder coated.

I'll make note if this, for future reference.

[Trevor from Warragul]

[Ellz10]

Thank you for that clip, I actually enjoy watching those types of videos and the powdercoat turned out amazing!