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I never tried to grind down the old weld. All I did was remove all of the stuff off of the axle housing (shock mounts and steering stops) then get a big a$$ pipe cutter and cut it apart that way. That seems to be the easiest way to me. I was nervous about just grinding away at teh axle housing. I think Woody does it the grinding way. But I seem to think he is out of town right now.
How deep have you gone??? And how far into the housing have you cut? the welds are super wide and deep. The housing is over .25" thick so it can seem like a really deep cut.

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