Metal Finishing

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I am making a TV stand and desk out of 1.5" square steel tubing.  I want to give it a "brushed" finish and then clear coat it.  I have been using a random orbit sander so far to get that effect, but it is taking forever.  I have tried a wire wheel also, but it does not seem to speed things up any.  Does anybody have any suggestions?Thanks,rigger
Reply:My guess is you need better sandpaper. I am assuming you are using cold rolled steel tubing, so it comes greasy, but without mill scale. So after degreasing, you need to use a pretty agressive sand paper in your random orbit. We have been doing a whole lot of brushed finish on stainless steel lately, and I use a bosch random orbit sander, with a klingspor PS33 sandpaper, 80 grit or so, which is a stearate paper, which is tough and doesnt load easily. If I want a real heavy brushed look, I use their CS411 sandpaper, which is a blue zirconia alumina sandpaper- this stuff really cuts fast, and lasts forever. . We also use an air powered DA sander- with peel and stick sandpaper in the same type, ranging from 80 to 120 grit, depending on the surface desired.Another trick I use is a scotchbrite type pad on a 4 1/2" angle grinder- most welding supply stores carry these, in about 5 different grits.If you use a wire brush, I would recommend a stainless wire brush on a 4 1/2" grinder as well- pricey buggers, at about 20 bucks around here, but they last a long time, and wire brush pretty agressively.All of these give slightly different finishes.You have to have a decent sander or grinder- I like bosch or metabo, myself. No subsitute for power.
Reply:What do you use for degreasing?  I've been using Gator Grit- 60 grit paper on my Porter-Cable random orbit sander and it doesn't seem to last at all.  I need to get a new wire wheel,  the SS one that I have is shot.  I've got a Milwaukee 4.5" angle grinder so I don't think that I am lacking too much as far as power, but I think if I can find some better sandpaper that will do the trick.  Do you know of any chain stores e.g. Lowes or HD that carry the Klingspor brand because I looked at their website and there isn't a store listed anywhere near me.  Thanks.
Reply:For degreasing, when you are young, dumb, and full of you know what, you use laquer thinner, or if you are even more full of it, gasoline or MEK or Trichlorethelene.Then, when you get a little older, and realize all that stuff can kill you, you start using Simple Green, or some other citrus based cleaner. Yeah, its a little slower sometimes, but you know the joke about the young bull and the old bull, right?Chain stores carry cheap bottom of the line mass market crap. If you want decent sandpaper, you wont find it there. You can mailorder direct from klingspor. Or use another high quality industrial sandpaper- Norton is good, and there are some good industrial 3M products. Try your local welding supply- if they are any good, they should stock real abrasives. A decent autobody supply store will also stock hook and loop and PSA discs in a stearate paper, that should work well.Abrasives, wire wheels and the like are called "consumables" cause they get used up. An unfortunate cost of doing business, but if you buy good quality, it will be worth it.
Reply:Thanks for the help.
Reply:I've noticed that Home Depot has started carrying Norton Abrasives.  Unfortunately, they're a bit expensive in small quantities.-Heath
Reply:Rigger...consider having it clear powder coated. I recently saw a bunch of tables/chairs that were done that way and they looked really nice.