Repairing and polishing planishing heads..

[imagedude]

A friend phoned me earlier this year asking me if I was going to be sniping an Ebay auction for a quantity of blacksmith and tinsmith tools plus an anvil. I was aware of the auction but as my friend wanted the tinsmithing tools we agreed that he would bid and have the pick of the haul.
The auction price went higher than expected but there was a good selection of tools so the deed was done.

As is often the case with Ebay, the tools are never as good in real life as they look in the photos. Below is a photo I took and you still can't really see the condition...

http://photos.imageevent.com/imagedude/blacksmithtinsmith/websize/PICT0055.JPG

When you look a bit closer you can see the true state of the tools...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0109.JPG

As my friend is a jeweller the heads were useless in this state. Now polishing isn't my favorite job as it's dangerous and dirty but he was obviously a tad dissapointed so I offered to make good the damage in exchange for the anvil and tongs that came with the planishing heads.

First I removed the large dents with a varispeed grinder fitted with a 60 grit disk and backing pad. These were £15 each from Argos, I bought four!

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0078.JPG
I use a varispeed as I find the 11,000 rpm of a standard grinder far too agressive and you can get local overheating which leads to stress cracks and soft spots if the dollies were hardened. Backing pads are prefered over flap disks when working on rounded objects (by me anyway).

Below we can see how the 60 grit disk removes the damage but leaves flats and course scratches which are not desireable...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0111.JPG

And again...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0110.JPG

Once the dents were removed I started with a bench mounted flapwheel of 120 grit. I'd have prefered an 80 grit wheel but did not have one available. The wheels are often known as unmounted or centreless flapwheels, picture below...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0087_1.JPG

They are available from www.thepolishingshop.co.uk in grades from 60 - 320 grit, £18 for 6" x 1" wheels and £30 for 6" x 2" wheels. If you can get them cheaper please let me know.
Below we can see how the flapwheel starts to refine the dolly. I find it easier to shape the dolly with the bench polisher than the angle grinder; by rotating them in my hand against the wheel I can start to get the round shape of the dolly back. In the photo below I have used the flapwheel on the right side only, hopefully you can see the difference in finish and see how the roundness is returning...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0089.JPG

Normally I'd polish the whole of each object before moving on to a finer grit but I'm doing half at a time to try and show how the process progresses. Below we see the finish improve as I move to 180 grit...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0099.JPG

Remember, there is no point changing to a finer grit until you know you have finished with the courser grit, it'll all end in tears if you try and remove deep scratches with too fine a grit. Below we see the finish improve further...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0104.JPG

And with a finer grit it gets better still, below we see the finish I get from the 320 grit wheel...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0102.JPG

Once we get a 320 grit finishover 100% of the workpiece we can then start with the polishing mop. If there are any deep marks/scratches left on the piece or we find that we haven't got the shape we require, then we need to go back to the courser grit wheels and start the process again! It pays to do it right the first time around. Below we see the polishing mop I use with cutting paste...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0108.JPG

A common mistake is to apply too much compound, a little is all that is required. Polishing mops will try and grab the workpiece out of your hand, if you're lucky only the work will be damaged. You have been warned!
Below we see the finish that cutting compound gives...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0107.JPG

I should have sucked my gut in for that photo, too late now!

Next I changed to a cotton mop and used a finer polishing compound...

http://photos.imageevent.com/imagedude/polishingadolly/websize/IMG_0105.JPG

And below is a set finished to 320 grit...

http://photos.imageevent.com/imagedude/dollies1/large/PICT0179.JPG

At all times throughout the process I was aware of how hot the workpiece was, frequent cooling was required. Eye protection is essential. In some of the images you can see how much airborne crap is generated, I would recommend at least a P2 standard dust mask is used.

[arian]

Excellent job. I've struggled with needle files (they break if you bend them too much :-( ) and emery before going on to the polishing stage. Hard stitched cotton mop and Steelbrite polish and a big polishing machine.

I remember seeing the EBay auction, but I think the price went too high before I sniped.

So long,
arian

[Underhay]

Looks like you've made a silk purse from a sow's ear to me :)

Enjoy the anvil and tongs, they've been well earned!

[mloc]

all i can say is thats amazing work

[Edd-UK]

thats should be in the Tutorials Archive.

excellent work

[Yog]

Looks like you've made a silk purse from a sow's ear to me :)
I couldn't agree more. Great work !
I hope your mate really appreciates it.

[imagedude]

Here's how you make abrasive wheels the old way.

First assemble your tools, Coldax cement, coloured stitched wheel, grit, brush, marker pen, tent peg, hammer, plastic bag, Mail on Sunday.
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0031.JPG
Stir cement with tent peg
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0032.JPG
Don't know why I felt the need to photograph that, next clean the tent peg with kitchen roll and apply wheel.
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0033.JPG
Using a scabby old brush, paint wheel with cement.
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0034.JPG
Pour grit out onto non pourous surface (plastic bag). This will not stick to wheel (hopefully).
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0035.JPG
Roll wheel in grit ensuring even coverge.
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0038.JPG
Mark grade of grit on wheel.
http://photos.imageevent.com/imagedude/polishingadolly/websize/PICT0039.JPG
Leave in the airing cupboard to dry overnight.

To be continued...

Using this technique you can make up mops/wheels of all shapes and sizes. They are more resistant to damage than flapwheels and more versatile but not so nice to use. I reckon it costs pennies to coat each wheel. This method of abrasive wheel making still has a place in the world of polishing.

[Singeblister]

You did a great job bringing those back, bet it took hours.

[MotorbikeMan]

Fantastic job, must have been very satisfying to see them done. With regards to the angle grinder, did you mean that the varispeed grider was £15 IN Argos, or the backing pad?

[imagedude]

Fantastic job, must have been very satisfying to see them done. With regards to the angle grinder, did you mean that the varispeed grider was £15 IN Argos, or the backing pad?

The grinder plus case and a few disks was £15.

[MotorbikeMan]

The grinder plus case and a few disks was £15.
:O I'm off to Argos :D

[Topcat02]

Excellent job! Would it be financially feasible to buy off ebay, restore and re sell on ebay.

I am amazed at the quality of the finished product.

TC

[arian]

The grinder plus case and a few disks was £15.

Looks like you got a bargain. According to Argos' web site, the £15 grinder (http://www.argos.co.uk/static/Product/partNumber/7105283.htm) is single speed; the variable speed one, with a case and stuff, (http://www.argos.co.uk/webapp/wcs/stores/servlet/ProductDisplay?storeId=10001&langId=-1&catalogId=3801&productId=149874) is £25 :( You should have grabbed all their stock :)

So long,
arian

[ZDP-189]

I have moved this excellent thread to the Tutorials Archive. If for some reason you can't post in here, please PM me and I'll move it back till it's finished.