Re: Polishing Cast Aluminum
nikos8,
I have successfully used a metal file to remove the mold marks from the casting process. They make files especially for filing aluminum. You can also use a diamond impregnated fingernail file to do the same thing. If you are using a die grinder with cartridge rolls, be careful they will gouge when you move from one direction to another. On flat surfaces you can use a DA sander, it will leave a nice flat surface when done properly! I would also recommend the greaseless compound to get the aluminum to the place where you can start to buff it. I would suggest that you get treated buffs ranging from 1" to 3" for use with the greaseless. When you start sanding your project, match the grit of your sanding media with the finish of the part you are going to sand. That's a good starting place! You can normally start to buff after you have sanded with 600 grit paper. I wet sand with that grit using water and a little bit of dish washing liquid. That helps to keep the paper from loading up. Prior to starting to buff wash your aluminum in hot water and dish washing liquid, Dawn. After you start to buff use acetone or brake cleaner to clean the aluminum.
There's plenty of information on the site on aluminum polishing, go through that it will give you further information.
John
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