I had a similar problem when I was sanding out the skid plate for my Banshee. No matter how I went at it, the surface would "orange peel" when I was working the part with 400 greaseless. I ended up having to hand sand the thing with 220 wet/dry, then 320, then 400 before I could start polishing.. The only thing I can think it might have been is just crappy aluminum..
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