Getting rid of excess weld metal...

[Woodsy0]

This might sound like a dumb question, but...

A friend and I just finished up welding an exhaust system up with his arc welder. There's a spot on the downpipe surface that mates to the o2 sensor housing that has a piece of excess metal on it from the welding, obviously giving it a small sealing problem. In addition, there's a bunch of extra crap metal around the downpipe flange, making it hard to bolt the downpipe up, since the nuts keep hitting the excess metal. I'm going home today to deal with it, just wanted to know if anyone had a tip for getting it off easily. Only thing I can think of is attaching a metal scraper piece onto the end of a drill and just sitting there until it wears it out enough, then putting some washers on the downpipe studs so I don't have to deal with alot of the metal near the base of the flange when bolting it up...Any other ideas? I feel like hitting it with a hammer and screwdriver won't do a whole lot to chip off the metal...Mind you this is the first time I've done any welding, so this might be a relatively easy fix with the right tool, just don't know what that tool would be.

Thanks,
Scott

 

[black92_tsi_awd]

Just get a angle grinder or use a hand file with some elbow grease.

 

[WatchItExplode]

If you have access to air tools, use a cut off wheel to cut off the bulk of the excess metal, then follow it up with an angle grinder to smooth/shape everything out.

 

[Woodsy0]

Thanks, I'll give it a shot tonight.