Quote Originally Posted by dogcaller View Post
I have a Dremel. What would you suggest grinding it with--is there a particular grinding bit you would suggest? It will be able to grind down a washer that a drill press with a drill bit couldn't cut? Is there such a thing as washers with softer steel? I need a ~2" OD washer with an ID of .25 - .30". I haven't been able to find a beveled washer with a large enough OD.

Maybe the real question is--Is there not a simple way to use a drill bit to bevel these out...?
Not a simple or easy way to use drill bit to make a countersink in washer. Almost impossible to "hold" washer while being drilled by hand or on drill press.

I have made aluminium washers by drawing them on 1/8"(x whatever width you need to get washer size) thick material, use counter sink bit to make center hole and bevel, then use hole saw to cut out washer.