I am trying to weld a cast aluminum side cover for a custom bike. I have welded cast before with much sucess, but this one is a little different.
I am plug welding some holes in the cover and need a perfect finish
for chroming. The problem I am having is I just can't get away from some
pitting around the weld perimeter. I have tried "cooking out" the impurities with the arc and then adding my filler. But when I grind the weld there is always some monor pitting. I have tried different fillers, settings on the arc "dig"and "clean". (Syncrowave 250dx) with no success. I am beginning to believe it is not reasonably possible to get a smooth, chrome ready finish on this thing. Any advise would be appreciated. Thanks....Mike