i just finished my first window but it has a lot of rough edges and uneven sides. how do i clean them up?
A good metal file and a lot of time will take care of rough edges. That or you could just file them down enough to use the moulding method of attaching the window, that will cover up the edges as well. -Jason
Ghost is correct. A decent file set is a must-have. I got a decent set at Lowe's for something like $11. I also picked up a set of needle files from a local hobby shop, I would highly recommend a set of those. You can get both types for reasonable amounts of cash.
A dremel's grinding stones /would/ work yes, but remember: the rougher the grinding stone, the rougher the finish. Nothing can replace a good set of files. -Jason
Best use a file and stroke diagonally. I'm after a diamond coated whetstone file soon - that should be perfect. Use your grinding stones if you have good control, but I'd favour an old fashioned file.
I only use a grinding stone for deburring... not for evening out un-straight cuts... the reason why is because it is really hard to get a straight line from a barrel shaped tool... a flat file is ideal for evening out metal... we had a similar conversation a while back about plastics but the same principals apply to this topic too...
When I deburred and smoothed the edges of my window in my PC, I used the grinding stones to smooth the cut, and also got a #511 abrasive buff to finish the cuts and give them a nice smooth finish. If you are straightening cuts, then I would definitely go with what eddie said about filing to make them straight.
as the others said a good set of files would do the job specially with aluminum casings, fine teethed files works best with aluminum also you could use a sand paper and sanding block for cleaning and deburring straight cuts...
just thinking, you know how on some metal edges you get that very nice rounded painted finish on it? i think that would be very nice, and (correct me if im wrong) would be easy to do just by filing all around the bend, like constantly adjusting your angle. i might have to try that.