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Originally Posted by x1rider
I am polishing an intake manifold and would really appreciate some suggestions on the quickest way to remove the cast marks. I tried a sanding drum with a dremel but it seems a bit aggressive and the drums last 5 minutes. I also tried a 1 inch 120 grit flap wheel, that went well but I went through the flap wheel in 20 minutes. Are there any other ways to do this? Thanks in advance.
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Cartridge rolls on a die grinder, felt bobs and small wheels with greaseless compound, sandpaper and elbow grease...no matter what you use it's going to be consumed in the process. Most economical (but slowest) is probably the greaseless compound since it's renewable. The Dremel won't have the guts to do much, only for tiny detailing in my opinion.
I used to start with 80 grit, but 120 is plenty. If I use 120 cartridge rolls I then also usually go over it with 120 greaseless to get rid of the ripples.
Do an archive search, there's plenty of stuff in here...