Nice welding
 

I had a custom built alloy racing frame which was quickly recalled after they found problems with the batch of tubing. :(

They smothed the welding on the original, and it looked absolutely gorgeous. However, the rebuild has come back with _ugly_ welding beads all over the joins.

They seem to be suggesting that it can't be smoothed down for structural reasons, even though it was before. I (in my usual untrusting view) am worried that they just don't want the cost of grinding it down and re-painting.

Does anybody have any knowledge or opinions about this sort of thing?

Thanks,
--Biggs

Smoothing welds does make the joint less strong, but whether it will make a difference I cannot say. If it was steel or Ti I doubt it would and I'd tell you to talk to them about, but since it's ally I say just leave it. If it's really ugly then by all means do something about it, but very few frames have smoothed welds, we just put up with it :)

My new Specialized Allez Comp frame has very smooth welds.

Cannondale
 

I don't own a Cannondale, but I think they used to claim that their smooth filed welds actually made a stronger joint. My Pinarello has finished welds and has a reputation for strength.

They wouldn't grind it down, but make a deeper weld using a different welding process. Machine welds of Aluminium are beaded.

They may have had to change the process if they changed the tubing.