...i do however make things out of metal everyday. can we hear more about tools,grits and processes ? tips,tricks and techniques? i remember patina turner saying he cut his discs a certain way...
I've been a silversmith for 30 years, a steel fabricator for longer than that, and I just started making knives a couple of years ago. No matter what metal or what the final finish will be - bare metal, paint, plated - there are a few things that I've found to be universal.
1) BE PATIENT. nuff said.
2) Change your media like it was free. Belts, pads, sheets, whatever, it's never worth trying to make them last. When the media quits cutting, not only are you wasting elbow grease, but you're creating gouges and grooves with an uneven cut.
2a) Cheap media is a lot more expensive than the good stuff.
3) Increase grit value x2 each step. In very high grits you might go up in smaller steps, but you never want to go more than double the last grit. Again, it costs you time to try to skip steps.
4) If you can, sand/grind/file across the grain of the previous grit. It makes it much easier to see the scratches left from the last step.
5) Sand those scratches out! It will NOT blend in, and the paint probably won't cover it up... Nothing worse than getting to 600g and realizing that that 240g scratch is getting uglier and uglier.
6) It's awfully easy to go too far, and damned difficult to put the metal back. Files, the proper sanding blocks and mandrels, and a good straight-edge are your friends.
7) An old bladesmith gave me this tidbit and it completely changed the way I approach finishing and sanding:
You never
remove a scratch or gouge.
You're removing everything that ISN'T that scratch.
When you look at things from that perspective, the whole process makes a lot more sense.
Doc