Whats the best way to do it then guys? and what tools will i need etc.

 

Cheers

Mathew

Try a flap wheel on a brill to start with and work progressively less course material. Getting in some of the tight corners is the toughest bit. Basically, just a lot of elbow grease and hard work :)

Flap wheels take forever on the Z plenum :( Get a sanding disk on an angle grinder first to get the larger areas flattened, then use a flap wheel to get in the awkward areas - if you're using it on a drill watch you don't hit any flattened metal with the chuck LOL ;) Do all this with the plenum well soaked in WD40.

 

Once you've done this, go over with fine grit wet and dry, again, dowsing the plenum in WD40 regularly.

 

Once you have a nice flat grey coloured surface all over, its time to hit it with a polishing mop. Go over the whole piece using the polishing compound until you have a nice gloss finish.

 

All thats left then, is to go over the piece again with a different polishing wheel but this time with glossing compound - this gives the glass like finish ;)

.....Do all this with the plenum well soaked in WD40.....

 

 

Andy? What's the WD40 for? reducing aluminium dust? or easier cutting??

2 reasons really, prevents the paper from clogging up as quickly, and also prevents the surface 'picking up' as you go over it....

 

Make any sense? Prolly not :D

 

CheerZ,

Andy

Flap wheels take forever on the Z plenum :( Get a sanding disk on an angle grinder first to get the larger areas flattened, then use a flap wheel to get in the awkward areas - if you're using it on a drill watch you don't hit any flattened metal with the chuck LOL ;) Do all this with the plenum well soaked in WD40.

 

Once you've done this, go over with fine grit wet and dry, again, dowsing the plenum in WD40 regularly.

 

Once you have a nice flat grey coloured surface all over, its time to hit it with a polishing mop. Go over the whole piece using the polishing compound until you have a nice gloss finish.

 

All thats left then, is to go over the piece again with a different polishing wheel but this time with glossing compound - this gives the glass like finish ;)

 

 

Superb mate, any recomended grits and polishes, and where to get them from?

2 reasons really, prevents the paper from clogging up as quickly, and also prevents the surface 'picking up' as you go over it....

 

Make any sense? Prolly not :D

 

CheerZ,

Andy

 

Nice one. Makes perfect sense. ;) :D As I thought, to aid cutting.

 

Thanks.

i can highly reccomend andy's instructions - as the plenum he did for me was superb