If I understand your problem correctly, the pressure and distance
from your accessory to your work can have a huge effect.
Can you send me a picture of the accessory you are using?
Until then try this. Take a few scraps of aluminum.
Measure the distance how far into the brush are you pushing the
metal of the wire brush, meaning from the bristle end towards the
are you using a flexshaft or are you using a fixed higher speed
polisher? If it is a flexshaft, then test the finishes at a few
different speeds and see the difference.
if it is a fixed speed polisher and the brush is large, find the
sample that works best for you and try to stay at that distance.
Sometimes holding your work and moving back and forth from the end
to the center with a fixed speed will give you varied and uneven
finishes. It’s imperative that you hold it as steady as you can. The
amount of friction and bite into your metal will vary greatly if you
can’t secure your work at a fixed location.
Lastly, keep a light touch on the piece. Sometimes we want to force
the metal into the bristle wheel. Let the wheel do the work, relax
your hand and I bet you will achieve a more even finish.
Otto Frei has them. They are not cheap, use them slowly and yes,
wear eye protection as the little pins can fly off like shrapnel.
However the finish is yummy. I made a little texture sample plate on
brass so I could tell which one to use. If you are using the lathe
mounted ones, you need to be right at the edge and be very, very
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I actually use those scary wire wheels which give me a great pebbled
finish on my work with a flex shaft.