Ha! Wait until it is done. <img src="/ubbthreads/images/graemlins/smile.gif" alt="" />

Status report...

I rigged up my Harbor Freight belt sander tonight and spent about 20 minutes fooling around with it by sharpening an old throw away knife and practicing grinding a wire edge. Went slow and kept the blade cool the entire time. That old ugle knife can cut paper now for the first time in it's life. <img src="/ubbthreads/images/graemlins/laugh.gif" alt="" />

After I felt a bit more comfortable I brought out the Ratchet and started to work on the flat parts, i.e. the rough stuff above the choil. What I found is that the belt has some flex in it and wants to apply a slight convex shape to the metal. This has the effect of smoothing the edges before the middle. The Ratchet has 2 inches of perfect FLAT and I'm having trouble getting the middle part with the belt. Any suggestions?

I can keep grinding and give the entire flat part a slight convex curve and that won't hurt it a bit, and I'll eventually buff out the middle, but was wondering if there was some technique to work on the flat metal parts. I have the belt as tight as I can go without creating undue movement and vibration.

What do you think?