If it's been "show-polished"... a media blast with black oxide to modify the surface profile will be MORE than enough to accomplish your goals. If it's a bare cast aluminum (we'll say an intake manifold for example... I always use that). Just take and knock off the casting flash if there is any, and most high-spots with a file of some sort. Sand paper isn't really going to do squat for you in this case. All of the "low" spots should be filled in with the Caswell Lab Metal ( found on the openeing page when you enter this site at time of reply) and then evened out. Just media blast entire surface after that to assure good adhesion. At this point, you may also use PROD ALCHROM880 for a good chemical bond on aluminum. Coat as normal and all will be fine. Powder coatings have this wonderful "hi-build" effect which makes them such an attractive thing for the hobbyist (and machinist to request) to use. They hide the sins, in plain English. Even more-so when you put a clear coat on top! (click on the sticky forum in here that has pictures and you'll see how amazing some of the people in here have achieved these same results!.... very proud of you all). What you will end up with is a smooth "glassy" appearance that has hidden a great deal of casting marks, scrapes,chips and the like. Hope that helps......Russ
p.s.- can somebody post the links to the Lab Metal and Alchrome880 for me? I'd give you the official non-stick thumb's up for the day if you could and I'm sure "thesound" would be eternally grateful for it as well. Thanks
