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Polishing the Aluminum and Chrome Parts

  « 1980 Ironhead Sportster Chopper

(Painting & Bodywork)

Polishing the Aluminum and Chrome Parts This sportster has a lot of aluminum and it all needs polishing. In particular, the cam, primary, and transmission covers, the fork sliders, brake calipers, master cylinder, and the rocker box covers. Many of the chrome parts are really beat to hell, especially the pipes.


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Beat up rear caliper
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A quick buffing got some shine on this caliper but the dents and deep scratches will require some heavier sanding and grinding

BEHOLD THE PORTABLE BUFFING WHEEL OF DEATH
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The tiny buffing wheel worked ok on the slower air die grinder but this electirc one was too fast and it fell apart. So I rigged a 6" spiral sewn wheel on a disc sander and held it on with an arbor nut off my angle grinder of the same brand.

Buffing the pipe headers
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The buffer was even able to remove the brown discoloration at the top of these pipes

Polishing the Fork Sliders
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I used the orbital sander to smooth out the rough area where the reflector would attach, and a cloth buffing wheel on a pneumatic die grinder to polish

Polishing the Primary Cover
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A buffing wheel on a die grinder quickly brought out a mirror finish on this hazy old aluminum cover

Rear caliper after sanding
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I went to work on this piece for a couple hours with a dremel and orbital sander to dig out and smooth the deep dents and scratches, then gave it a coarse buff to get it to this point. Not perfect yet but a big improvement

Rear outer caliper body
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another shot of the aluminum caliper body after being sanded smooth

Right Side Covers
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This shot shows a good comparison between the buffed and un-buffed areas

Slider and wheel
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Coming along but I still need to pull the calipers off for restoration

WITNESS THE FURY
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The buffer of death made short work of this surface, it even removed the raised logo from the middle of that circle

   



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