removing deep scratches from DOHC engine side cove

I bought used 'DOHC' engine side pieces for my '78 kz1000 and I want to remove some deep scratches in the aluminum, about 1/32 deep in the worst scratched area near the bottom.

I don't know *exactly* what tool to use.
(I should be able to use myself as I AM a friggin tool sometimes.) :blink:

I'm thinking either my Dremel or my handheld drill.

But I have never removed deep scratches from the kz1000 (soft?) aluminum side case covers, actually have never removed deep scratches from ANYthing.

Anyone have a suggestion about what type of Dremel attachment to use or what type of buffing or grinding wheel to use on my hand drill?

I have the same problem and wet sandin just aint getin it !!!!!!!!!!

block sanding is best way i know of fixing it,dremel will just leave waves in cover

PLUMMEN wrote:

block sanding is best way i know of fixing it,dremel will just leave waves in cover

I was afraid of that, waves. Plummen, what grades of sandpaper work for this? Do you start with, say, 40 or 60 to remove enough material to go flat, then do a 100/200/400/600 series using a sanding block? And is wet sanding the way to go?

depends on how bad the scratches are,using much meaner than 80 to start will leave lots of new scratches to sand out.if theyre reall bad you can start with a file to save some work then go to block sanding.depending on finish you want you can wet sand when finished or use aluminum polish.

I'd start with 100 grit... Not too much and work up from there... Take your time and only hit that specific area with the hard stuff. The finer you go youll cause less damage.

Follow the link named BUFFBOOK.pdf...
Provides everything you need regarding buffing....

kzrider.com/index.php?option=com_docman&...d&gid=427&Itemid=108

It's the basics of what I used and my cases even had holes in them....:blink:

OMR

Almost forgot, my favorite for Plummen and Patton....

Fabbed and buffed out under tail section....

I had a very bad road rash one, that i bought on eBay. I first removed the damage on a belt sander and than started using finer and finer sand paper until it was gone and I could buff it out. It only took about 20 minutes to do and it is almost impossible to notice now, because everything is blended evenly.

The bitch is scrubbing a fresh powder coat cover then having to repair with out starting from scratch.

Lucky in my case the stator cover FU is on the bottom but still noticeable, to me. Not many lookup at a KZ. I'll be able to get away with a touch up with some gloss epoxy case paint and it will not be noticed.

Makes me think twice about powder in the future...

How is it respraying guncoat if a oops occurs?

Although I admire and appreciate a clean polished motor I know it's not for me.

otakar wrote:

I had a very bad road rash one, that i bought on eBay. I first removed the damage on a belt sander and than started using finer and finer sand paper until it was gone and I could buff it out. It only took about 20 minutes to do and it is almost impossible to notice now, because everything is blended evenly.

Sounds efficient -- the less time it takes to work through menial stuff the less chance you'll put off doing it!



I VERY much appreciate the other advice here!
I took 80 grit with a sanding block as Plummen suggested and got the right side DOHC ready for finer grit and buff, thanks Plummen.

I'm checking out that link too Rock, thanks.

But the left side DOHC alternator cover is bad and I think I'll try the belt sander -- I own a belt sander -- and the scratches are deep -- Otakar, what grit did you start with on the belt sander? I reckon I'm at 1/32" at the deepest....

Random orbit sander, will not leave whirl marks, best damn sander I've ever used, and I use it in all applications,woodworking,auto body,just anything you sand this beats all other forms,belt, disc, block hands down. regards Duke