Thanks for continuing the illusive search for a good finish, Brian. Nice build but was surprised about the welding on AL...a tough do!
I built a little holder for my Dremel flex shaft on the Mini. Definitely mixed results. A few of your YT viewers hit on the issues I ran into also. Proper wheel choice, a true wheel and the bearings are what I found were the culprits. Also the 1018 is a bit gummy as someone said. The Dremel only has one bearing on the front end, in a plastic housing. Lots of flex and will chatter like a banshee squirrel primarily because of the 1/8" shaft. Your die grinder is in a metal housing but bearing quality is probably low. One thing that did work pretty well were grit impregnated rubberized wheels similar to Cratex...the finish was pretty good on most materials.
I've been on the hunt for something with dual bearings in the front. I looked at Foredom and theirs is quality but single bearing...just out of my price league. Have considered making one but the square cable drive would need some fingering for my meager shop!
Thanks for sharing your build and results. ~PJ

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