outside sq. tubeing corners

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I am wondering what are some production short cuts for cleaning up outside and inside 90 degree joints on square tubeing after it has been welded. I figure it is the old 4.5" angle grinder, and maybe a bandfile for the inside but thought I'd ask anyway.Thanks
Reply:Outside corners are not sharp, but cut as 90˚ notch, prior to welding. I don't have a compoundmiter saw, so the length is cut 1/4" short (1/8" wall tube), then separate operation to miter. If not doing what I do, then grinding the outside verticals to create a 90˚ bevel weld priorto fitup, does the same thing.         After fully welding (with ground bevels on the top/bottom miters), the outside corner,tops and bottoms are roughed close to surface with Pearl Flex 36g flexdiscs. Flush finishwith Avos type (norton or carborumdum) sanding discs. This is fast, gives good lookingfinish. The 'see-thru' holes in those discs show what's happening and help to avoidmarks and gouges. To rough then sand flush the top/bottom sides and outside corner on 1 1/2" tube is about 3-4 minutes total.Inside fillets--either make a nice looking weld for no sand/grind....or have at it with carbideburr in air grinder. The burr can make a decent looking faired radius out to the top andbottom sides.Blackbird
Reply:I get some .065 square tubing work on occasion, and get to leave the inside weld alone.  I use 60 grit flap disc to knock the outer welds down.  The prints don't call for a super  nice finish, just "grind welds" so they're flat, and the pieces can be bolted up against a counter top or 2x4 frame (wall).Why are you having to do something to the inside weld?  Fixing mistakes?  There are flap discs that are designed to get into corners and knock welds down.  They work fairly well, and you can also use them as regular flap discs.-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:what has already been stated for outside welds.   For inside welds, weld betterVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.