I posted something similar in the framebuilders forum, but I wanted to get a few more opinions.
Is there any danger in smoothing/filing/sanding/Dremel-ing TIG welds to achieve that smooth "Cannondale look"? I mean...a number of companies do it, but do they make the welds with a load of extra material to sand down, or do they just use the weld as it is?
I'm considering doing some cosmetic work along these lines to my commuter bike and then powdercoating in a single color. My commuter is the matte black Nashbar "X" Cyclocross frame...it's a plenty "beefy" frame, and I've been told the welds look like very good, very strong welds.
Opinions appreciated before I go do something catastrophic!