This is as far as I've gotten on the plenum and will post up more pics as I finish it. Pretty much used an electric palm sander starting with 60 grit, moving to 100, 220, 400, 800, then 1500. I still have 2000 to use and then get it on the buffing wheel after that and will post more pics.

about 45 minutes with 60 grit


about 15 minutes with 100 grit


about 15 minutes with 220 grit


about 15 minutes with 400 grit


about 15 minutes with 800 grit


about 15 minutes with 1500 grit, and as you can see, some of the "whiteish" spots were low spots in the casting that I missed with the course grits and thought they're probably come out as I went but they didn't so I went back for about 30 minutes starting with 60 again in those spots and worked back up to 1500 again

 

off to a great start. it takes a lot of work to get those cast parts smooth, doing a great job. must say, you're more patient than i too, haha

 

looking good...took my forever on my 87 Formula But it was worth it...

 

You need more time with the rougher grits. But it looks good

 

sorry for the delay in progress, but finally did get some more done and took some pics.

Here I spent about 15 minutes with 2000 grit dry. I did notice that as this stage, the 2000 can start to clog easily, so I was whiping the sandpaper with a paper towel and it seemed to clean it up a bit.


Next I hosed the whole thing down with just regular silcone to act as a lubricant. I didn't wanna use water since last time I did that, my grandfather's palm sander started rusting in some spots and got greif for that. In my opinion, the step is where the real shine really starts. This pic is about about 15 minutes with silicone and 2000 grit before cleaning it off.


After cleaning up with a mild simple green solution, compressed air and whiping down.


This one is after about 30 minutes on the buffing wheel


After about 10 minutes and hand rubbing with aluminum polish


There are still some details that need some attention, mainly the sides (edges and corners and such). I will post more on how I get those touched up with some felt polishing bits in a diegrinder. Also, I plan on hitting it a few more times with the aluminum polish by hand.