If you're going to polish them then about the only way to fix the 'chunks' is to TIG weld them. Then again you have got to figure the cost of the repairs versus the cost of another set of wheels!
Your wasting your time and money using all those different grits of paper. Match the finish to the surface to be polished to the grit of the sand paper. The Emory rouge is about 400 grit so you won't need to use any finer grit paper that 400 grit!
Try using a flap wheel on your spokes to smooth them out. There fairly pliable and should contour to the spoke.
John


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