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Old 02-18-2012, 01:40 AM   #29
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We have had good success installing and polishing the new segments from the factory. It isn't easy but it can be done. The new clear coat cannot be removed with chemical strippers. We start with a 300 grit sandpaper on a pneumatic dual-action sander to remove the clear and the mill finish (not brushed) to a smooth surface. We follow up with 600 grit and then 1000. Each set must remove all the scratches from the previous step. When we are finished sanding we go after it with one of our drum polishers and Green Ox compound. We then use a couple of Nu-Vite grades, ending with "S - Final Finish" to protect the shine.
The process takes about 2.5 to 3 times as long as the original metal but it can be done. The two segments marked with red arrows on the 1971 Safari tandem were replaced with the new material.
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Old 02-18-2012, 04:43 AM   #30
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... and how much material are you left with Brett? I cannot see removing that much aluminum and having very much skin left. Could you post some photos of the two segments side by side please? From 30 feet it, under florescent light it looks a good match. In the light of day I think the color of the metal will be very different.
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Old 02-18-2012, 12:06 PM   #31
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We remove so little metal the difference cannot be measured with a micrometer. We star out with .040 aluminium which has been stretch formed and probably varies from .040 to .037 We remove less than .0005". This is far less material than is taken away when a tree branch scratch has to be sanded out. Keep in mind the sanding process is accomplished with super fine grades of paper.

I will get photos of another unit,in the sunlight, at close proximity, and post them here.
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Old 02-18-2012, 02:18 PM   #32
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Custom multi-segment end caps would be cool. They are also easy to repair since they are flat sheets not die formed.

Perry
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Old 02-19-2012, 05:53 AM   #33
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Thank's Brett. Always looking to learn something new...
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Old 02-19-2012, 08:12 AM   #34
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Where is Darkspeed?? I miss him!

Sue
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