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Originally Posted by 68commando
Ok Guys,
I got the rotary orbit sander and some papers. I took the breaker cover which I had sanded by hand and polished and it still had some file marks in it. I used the 220 paper with the sander which seemed to take out all the file marks fine and even the rough aluminum casting marks. Of course the pits come and go. Then I sanded with 360, 400 (because I had it), 600, and 1000. Then I polished it with the black compound, brown, and white. The result is below. There are still some fine scratches in it that could come out, but no file marks. There is still a rough appearance to it if you get up real close or look under a magnifying glass, it looks sort of orange peelish. You can see it in the pictures. But from 3-4 feet away, it reflects images pretty good. Doesn't have that blue tint like chrome. I am wondering if I the roughness is just part of aluminum? That cover which is 3" in diameter took me about 3 hours.
Dave
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The orangepeel and pores are just due to the material itself. The deeper you go the more pores will probably appear so don't waste too much time on them. The orangepeel, I've concluded, is from varying densities and also not really fixable (although if you use geaseless compound it will do that to any broad surface). If you want a show bike, get everything plated; but the cover looks just dandy to me if it was on my bike. If you have scratches that only show up at certain angles, you could go back and work on them but no sense in driving yourself nuts over something that no one else will notice.