LOL, my secret. Bloody mindedness if I'm honest. I like to experiment, I'll get an old piece that if I ruin it it's not the end of the world, I watch myself doing things and try and analyse why it's not working or why it is, I buy stuff just to test them and see how they turn out. I started off by hand polishing, sorry, sod that, I had no fingerprints left, my fingers were bleeding, not kidding. I had to stop for days to let them heal. So I tried using a Dremel, I burnt 3 of them out, again, not kidding, luckily they have a 2 year warranty so they were all replaced. I have 5 Dremels now, if you're thinking of buying one do not buy the 3000 or the 4000, must be the 4300. It's a genuine improvement on all the others. Use a flexible shaft on it, that makes a huge difference.
I've found some flap wheels for the Dremel that come in different grades instead of the usual 80 grit. They go down to 40 and up to 320. I use them a lot, I also use plastic abrasive wheels, they go up to 2000, which TBH is so fine I can sand my hand with it and it doesn't take skin off, 2000 grit is far too fine for alloy, it's like a pumice stone.
For the buffer, I use a converted grinder, 650w motor, let the soap (as we in the UK call it, buffing compound to you) do the work, pressure works but it can dish the alloy if the soap is aggressive. I use felt mops a lot, with grey soap, the most aggressive, go down to pink for the next polish, then white and finally gold or yellow. If you've prepped them correctly they'll polish up with no effort or time at all.
That's basically it. Kelly, that motor is like a negative of mine, my barrels and head are black with the rocker cover silver, breather cover polished, tappet caps polished. I had the head and barrels ceramic coated satin black but smoothed all the fin edges first, took all the rough spots off them and then polished them, then had it coated, then resanded the edges and repolished the edges again. Not 100% done yet as I then found some water damage I'd missed somehow on the liners so I'm having it rebored. I also have a NOS set of barrels for a 550F which I'm considering doing the same to IF the reboring doesn't work as planned. Nice to see I'm not on my own doing the casting mark things mate, hate them.
Can I just point out, Honda painted these casings, they are not polished and lacquered. Sand one and find out. This is a CB650 points cover, NOS,
Just sanded lightly. You can see the paint layer just under the lacquer as the lacquer starts to thin out
A little more, bare alloy showing now with dark grey on the edges where the paint layer is still present
Some more, and really clear there are layers on there. Some lacquer, some paint. You wouldn't get that with polishing.
Sorry if I'm hogging the thread a little.