Aluminum Finish How to??

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Just looking  for some ideas on how to finish some 3003 1/8" sheet aluminum on a small box, blend in the welds, hide some imperfections... ect  What finishing discs are used/recomended? Procedure? I've used the Rexcut bending wheel on the welds. Would like to "texture/swirl" the rest of the surface. Tried using a angle die grinder and a drill press with a scochbrite 2" pad on some scrap... didn't have much luck. Thanks,quinq
Reply:For getting irregular swirls, a "dual-action" air-powered disc sander with the eccentric, free-floating  option would work well. Something like the Ingersoll-Rand Model 311A shown HERE.
Reply:Been working in metal 23 plus years, but only go to this board once in a while. Created a new user name because I couldn't remember my old one...I have good luck with creating the swirl pattern or "engine turning" with the right angle air die grinders with the 2" roloc scotchbrite type of pads. No matter if I am going to paint an aluminum piece or polish it, I start the same way. I clean the part with a watered down soap solution, scrubbing the part with a green pad. The type of green scrub pad that you can get for washing dishes at stores work fine. They sell dedicated pads with different levels of texture and color at automotive paint supply stores. Anyway, Clean the aluminum only going in one direction and with the grain in the metal. Aluminum has grain that runs in one direction sort of like woodgrain. This will help remove or hide any light scratches on the surface. Keep on cleaning until you get what is called a "water break free surface" that is when water poured onto the aluminum will flow over the piece evenly without beading up. If I want to paint the part I start with a preprimer wash called alumaprep and go on from there.Practice the swirling on a scrap piece. Use the 2" scotchbrite pad or sanding disc on the right angle die grinder, whatever leaves the swirl you are looking for on the type of metal you are on. Secure the work piece and hang on to the grinder with both hands. The grinder of course will kick if the whole pad touches the surface at the same time. I try to slightly rock the pad around so that it is less likely to kick. I lay masking tape next to the area that I am going to swirl next to but just outside so the tape won't touch the pad. This helps align the rows so they come out straight. Play with the over laping amount that looks good to you. I have done it on a milling machine at low rpm but the hand held way seems to be less of a hassel.That's my 2 pennies.IanMiller Syncrowave 200
Reply:if your looking for a smooth near polished finish nylon mesh wheels for a angle grinder are the way to go.  They remove any imperfections very fast and leave a smooth surface with no scratch marks.Have we all gone mad?