Re: craters, craters and more more !
I don't see any reason to outgas 6061 unless some hack is trying to cast with it. And NEVER sand on anything until it's been cleaned. Sanding will drive the contaminates into the scratches and will be hard to get out. Your compressor and Erich's point about the silicon spray is the reason I asked about your shop environment. He's right about vapors and mists hanging around the shop. You could spray a spritz of that stuff and the droplets could hang around for weeks. It can contaminate everything in the shop and be transferred by touch like a virus. I personally don't even allow the stuff in my shop.
The compressor can be a big source for contaminates too. Always use a separate hose for painting and PCing. If you have air tools and use a filter/oiler, that hose is contaminated with oil. Use a separate outlet (manifold with filter/dryer) to handle clean air needs. Make sure you use a water trap just before the hose and a filter/dryer at the PC gun.
The craters are caused by contaminates. Either in your air supply or in the air around your shop. Clean that up and the problem should go away.
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