How to Smooth Aluminum

by Randall Shatto

Smoothing aluminum is necessary if you are going to polish or paint your metal. The texture of the aluminum dictates what you can do with it. To remove scratches and blemishes, you will need to smooth the aluminum before you polish or it will not hold a mirror-like shine. In addition, you will need to polish more frequently to keep the shine in place.

Step 1

Decide how big the area is that you need to smooth. If it is large, a sander may complete the job more efficiently. If you were trying to smooth a small piece of aluminum, sandpaper is perfect for the project.

Step 2

Use 160-grit sandpaper for deeper scratches and blemishes. If the aluminum has only mild scratches, 230-grit sandpaper is sufficient.

Step 3

Sand the aluminum. Gently run the sandpaper or sander over the area you want smoothed. Use a back and forth motion and do not press hard. Only a little force is required to remove scratches and blemishes.

Step 4

Wipe the aluminum with the soft cloth. Remove the excess filings. Look closely at the aluminum that you are smoothing. Check for scratches or rough textures.

Step 5

Repeat steps 3 and 4 if the surface is still rough and has scratches.

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