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i never really thought of just using a drill, but that would work just fine. Just set it to the highest setting and turn the torque way down. Just use a a grinding wheel ( it looks like a cutoff tool, but thicker). And it isn't very hard to pick up on, so you should do fine.
 
You could lay down some painters tape around it and just use sandpaper or emery cloth on it.
 
K10 said:
willister, i never thought about just sanding it...might take a while though?
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That's just a small burr, the standard way of removing it is to use a bit of sandpaper or a hand file.
 
Aluminum is pretty soft and like Zero said, it's small. Just cover the area around it as close as possible with some painters tape and cut out some small pieces of sandpaper/emery cloth (maybe ~2"x2") and work at it in a circular pattern. Should only take a few minutes (if that long) to work it down. It'll probably leave some surface marks though so take your time with the prep and make sure you cover as much as possible if you care about the end result.
 
Before you go ahead and and remove the burr, is the screw tight in the hole? If not you might be better off taking a punch and hammer and flattening the hole.
 
If the screw is catching on the burr it'll probably be loose afterward, though you could use a screw/bolt and nut on it. As for the burr, you could put a little piece of metal (or something harder than the aluminum) on it and hit it gently with a hammer or rubber mallet while supporting the back side. That should push the excess back in a bit then take a drill and make a pass or two through it. Just clean up the edge of it afterward. But I'd probably just sand it down.
 
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