Tips/tricks for sanding/polishing brass
On Jim Bode’s website, I was able to pick up a “bronze” (don’t know the exact metal) cast version of the head used in the Studley Toolchest. It is a rough casting and I will need to sand/polish it up. I don’t have any power sanders. Do any of you have suggestions on how to go about polishing this? I’m guessing to start with some files (which I will likely need to buy) and then finder grits of sandpaper.
I will do it outside (metal dust mess) and wear some sort of dust mask. I think bronze/brass contains lead in it and I shouldn’t inhale it. I will research this but was wondering if beyond a dust mask, nitrile gloves, working outside, etc if there are any special precautions you would use for a lengthy metal working session. I’ve never sanded/polished metal. Many thanks.
Replies
I've finished a few of those. They are cast by Bill Martley in 2 sizes (1 and 2 pounds), and in several different alloys of brass and bronze. The one pounder is extremely close to the famous mallet in the Studley tool chest. That's the one you have.
You can follow Bill on Instagram (@mystic_pickers), and you can search for studleymallet on Instagram to see how folks have finished theirs.
The sides were partway finished on a belt sander. You could do that with a finer grit to get it more finished. The top, bottom, and coves are rough cast. You'll need a round file for the coves, to start. And a flat file for the flat areas. Bronze and brass are often tougher to file than steel. The best file is single cut, and a new, sharp file is far better than one that's been used on other projects.
File what you can, then use sandpaper to go through grits. Use a wooden backer to keep the flat parts flat.
You can use a buffing wheel, but it takes some skill. You will round over parts that you don't want rounded over, in a hurry.
Sorry for being long-winded.
Thanks for the info.
Use emery cloth for fine sanding with the grain and Brasso polish for the sheen.
I have cleaned up many metal and plastic surfaces with a 1/4-sheet Makita finishing sander. The pad on it is a rock because of its age. once you are all the way to 600 or so on the wet/dry paper you can switch to crocus cloth for a nice semi-polish. Beyond that you can use a polishing compound, but I would also avoid a buffing machine. Safer to do it by hand.
Sorry, I don’t have an answer for you, but your question reminded me of a story I heard decades ago. A reporter was doing a story on a local brass door company. While touring the shop he saw an old guy polishing a door the whole time he was at the shop. He asked the guy how he knew when it was done. The guy said, “It’s never done. Someone just comes and takes it away.”
Thanks all for the feedback. Since I don't own any power sanders or a buffing wheel. All of this will be done by hand. Looks like I need new files and will just take my time. I have a day job that has all kinds of deadlines. With woodworking projects I don't get stressed by how long anything takes.
I did mine with files and then sandpaper while watching TV. Just spred a tool over you or you'll get bronze dust everywhere.
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