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How-to: Polish an aluminum manifold

How-to: Polish an aluminum manifold

Table of Contents
Re: [gti-vr6] Polished Manifold Jim Bazzano <Jim_Bazzanozd> Thu, 11 Jun 1998 13:51:17 -0400
Re: [gti-vr6] Polish the manifold intake of there vr6? Jim Bazzano <Jim_Bazzanozd> Tue, 16 Jun 1998 09:38:37 -0400
Re: [gti-vr6] Manifold polishing Jim Bazzano <Jim_Bazzanozd> Wed, 23 Sep 1998 09:44:39 -0400
Re: [gti-vr6] Polishing the Manifold MAObereraol Fri, 26 Mar 1999 00:42:21 EST



From gti-vr6-ownerdev.tivoli Thu Jun 11 13:11 CDT 1998
From: Jim Bazzano <Jim_Bazzanozd>
To: dandcaed
Subject: Re: [gti-vr6] Polished Manifold
Date: Thu, 11 Jun 1998 13:51:17 -0400
Cc: gti-vr6dev.tivoli
 
I have done an "OK" job.   Fact is that its really difficult to work around
the runners while the intake is on the car.  Even when you take off the
plastic guard above the radiator, the dip-stick tube is still in the way.

The way I did it was:

1st  I used a 5" random orbit sander with #120 paper to remove the rough
surface.

2nd Once the runners are smooth to the touch, I went on to #200 sheets by
hand

3rd Then wet sanded with WD-40 as a lube, through #300, #400, #600

4th Hand polished the rest with Never-Dull

Results:  I can see myself in the runners - But the reflection is not as
"mirrored" as I would like. It needs a final touch by a buffing machine
with some compound - (or something along those lines).

Time: Over 3 days about 4hrs each day (lots of elbow grease)

Overall: If I had to do it again, I would seriously consider getting
everything I would need for the job and take off the manifold.  This way
ALL of the polishing can be done with power equipment and be done in 1 day.

When I got the car it had a few tiny dings in one of the runners (about
1/8th" wide)  and they were too deep to sand out. Just another flaw I am
stuck with.

Jim
------------ Previous Message from  Dan <dandcaed>  on  05/10/94
02:01:30 AM ----------

Has any one polished there manifold?
I heard it can be wet sanded then buffed and polished. Before i start
sanding i want to get all the tips I can on it.
Thanks
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From gti-vr6-ownerdev.tivoli Tue Jun 16 08:42 CDT 1998
From: Jim Bazzano <Jim_Bazzanozd>
To: Patrick Sherman <patrickvolkswagen>
Subject: Re: [gti-vr6] Polish the manifold intake of there vr6?
Date: Tue, 16 Jun 1998 09:38:37 -0400
Cc: GTi Mailing List <gti-vr6dev.tivoli>
 
------------ Previous Message from  Patrick Sherman
<patrickvolkswagen>

Has anyone polished the metal intake on there Vr6? I would like to know
what
you did? Sand first, then polished? I was thinking throwing a sanding bit
on
my drill sand it and them polish it.. Any recommendations, how-tos, dos and
dont's??
__________________________-

Uhhh yea , like, I posted a step by step on how I did this last week dude .
Here's some cool polishing info (was for bikes) gives some good detail
about how to proceed and materials required.

http://zx.labiker.org/howto/

Andy could you maybe stuff this link in your archive?
thanks
jim


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From gti-vr6-ownerdev.tivoli Wed Sep 23 09:27 CDT 1998
From: Jim Bazzano <Jim_Bazzanozd>
To: Dave Moak <dmoakglobalsite>
Subject: Re: [gti-vr6] Manifold polishing
Date: Wed, 23 Sep 1998 09:44:39 -0400
Cc: GTI list <gti-vr6dev.tivoli>
 
------------ Previous Message from  Dave Moak <dmoakglobalsite>  on
09/22/98 03:28:56 PM

I have read the Library entries on polishing the intake manifold, but I'm
wondering if there is an easier way to do it, rather than doing most of the
work by hand. Has anyone used a Dremel or similar tool for the job? Which
attachments did you use -- grinder, polisher, etc. Obviously this job is a
lot easier if you remove the manifold. How difficult id it to take the
thing
off?
---------------------------------------------------------
Dave ,

You will want to talk to VR6RAGE, (real name-- uhhh mike?), He is the guy
who gave me the tip on getting the polishing compounds needed to get the
mirror shine (something I have not done yet).

As for tools, a Dremel is just a bit small for this task IMHO and would
only work in the final stages of polishing anyway. I did the initial rough
sanding with a hand held  random orbit sander, but after that is a lot of
hard work with fine grit wet paper. Lastly, a high speed polisher with a
bonnet is used with different grades of polishing "rouge" to get the mirror
shine.

Jim





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From gti-vr6-ownercobra.ccsi Thu Mar 25 23:45 CST 1999
From: MAObereraol
To: U1arunitaol, gti-vr6cobra.ccsi
Subject: Re: [gti-vr6] Polishing the Manifold
Date: Fri, 26 Mar 1999 00:42:21 EST
 
You REALLY REALLY DO NOT NEED TO REMOVE THE INTAKE MANIFOLD!!  If you take off
the front motor mount and jack up the engine, you can get to all of the parts
that you would want to shine!  Removing the intake manifold is an unnecessary
hassle and could cause problems if you do not do it right.  Believe me on
this..

Matt
95 Vento GLX "Can see myself in my intake manifold" edition
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