*** Cross References to the other two supporting threads:

http://www.bikeforums.net/classic-vi...anodizing.html

http://www.bikeforums.net/classic-vi...irty-deed.html

Okay, away we go on the next step of the adventure:

FILING AND SANDING:

NOTE: Due to loss of original photos, both on BF C&V and my own personal archives, I've had to scale down the description here. Suffice to say that the basics of filing/cleaning up scratches is pretty much straightforward enough. I hope the few pics uploaded here will suffice.

You want a pretty varied set of files for whatever you may come across. I've had stuff that was beaten-up so badly I wanted a belt-sander

However, I've been able to get everything using the sets below. Mainly, my tools consist of a set of rough-files (carbide-granule covered) and finish-files:



Here's what we're starting with: a pair of Campy Ergopower brake levers supplied by our own Gomango. Note the deep gouges. We'll need to start with the rough files:



Note how deep the gouges are. In this case, they're a bit spread out. In other cases, you might end up with a deep nick/scrape in only one area. To clean up something like that, you'll want to feather the filing out from the gouge - otherwise, you'll end up with a noticeable depression which will do your aesthetics no good at all.

This is what it looks like once we've begun the rough filing - note we need to be careful and feather a bit around the factory engravings. We don't want to lose any detail if we don't have to, but in some cases - depending on where the gouges occur - there will be little choice. We can't put metal back once it's gone! Something to keep in mind while we're filing; take it slowly and deliberately:



Finished with rough filing. The unsightly gouges are gone; now it's just a matter of smoothing everything out:



Rough file at top, finish file below:



Smoothing out can be done to your own personal satisfaction. Some people will be happy with a finish that polishes out to a satin finish while others are looking for a mirror-shine. It's all up to you.

I use sanding films, Scotch-brite pads and flexible sandpaper in addition to the finish files. Normally I use the finish files first, getting rid of most of the rough file marks, then progress to the Scotch-brite pads, sandpaper and finally fine-grit sanding films (I get these last from my local hobby shop).

Note the ball of steel wool - this works wonders, too. Brass wool is even better:



The subject levers after completing the finish file/sanding. In this case, I took them pretty far and they polished up very nicely:



Gouges completely gone - and no unsightly dip/depression where they once were. Feathering paid off handsomely here:



And finally, here they are with a medium-polished finish - and a little drillium slot added for good measure:



DD