Zephyr has been helping truckers make metal mirrors for over 27 years now. From the beginner just starting out on their own rig, to the pro who does it every day as a career. For us here at Zephyr there is nothing more satisfying than seeing all of your metal transformations take shape with our Pro Series Products. We hang our hat on being able to provide you with the highest quality metal finishing products available today. The amount of pride in the trucking industry is second to none. Especially the pride in your rides. There is nothing like a freshly polished big rig pushing down the line. So, if you don’t find yourself near a polish shop and you don’t want the parking lot polisher touching your ride, we hope you can fall back on these easy steps to achieve a perfect shine every time.
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Safety first. For this particular process we will be using airway buffing wheels which will require the use of safety flanges. These innovative flanges are molded from high-density composite nylon that are lightweight, yet strong as aluminum. These flanges need to be attached to each side of the buffing wheel and are mandatory when using airway buffing wheels. Next, is your personal protective gear which is just as important as flanges. This includes ear protection, hand protection, eye protection, and most of all respiratory protection. These items are all available at your local Zephyr distributor or at www.zephyrpro40.com they are definitely a must when machine polishing.
Now, on to the “tools of the trade”!! For these wheels we will be using a 3 step process; cut, color, and finish. We will be using some of the most popular products from Zephyr. These products are available at www.iowa80.com
The supplies you will be using today:
- Variable speed Sander/Grinder 0-6,000 rpm
- Safety flanges & Personal protective gear
- Airway buffing wheels – yellow, green, white
- Compound/Rouge – tripoli, moss green, blue moon
- Wheel Rake
- Zephyr Pro 40
- Microfiber Towels
- Pro 50 Eliminator
Primary Cutting – 3200rpm For the first step we will be using the 8” yellow mill treated buffing wheel and tripoli compound. First off, rake the new buffing wheel and fray the edges. This breaks the buffing wheel in and allows it to more easily accept the compound. Remember, the buffer spins counter clockwise. So, be careful when applying the compound. Hold the bar of rouge on the buffing wheel working it from edge to edge for about 3 seconds. First, break the wheel down into sections. Start with the face of the wheel and work your way out to the edge. Left to right, bottom to top with nice even passes. You don’t want to apply too much pressure, let the grinder spin freely. Take your time and make sure you make even passes. Overlapping each previous pass. Move up slowly and push your black line of compound steadily forward. When you notice the black line start to fade you will need to rake all of the old burnt-on compound off of the pad and then reapply more compound, then repeat. This is the most important step in the polishing process. If this is done correctly, then you will have really laid the ground work for a beautiful mirror finish. The rest is downhill.
Secondary Cutting – 3200rpm Now, you should have a very shiny surface with a light haze and what looks like hash marks. This is perfectly normal considering this was just the first step. Now, grab your green buffing wheel and green moss compound. Rake your wheel just like before and apply compound to the wheel. Again, start from the inside and work your way to the edge. The moss green rouge is a higher-end jewelers rouge which will provide you with that high luster, show quality shine. This should leave you with an almost perfect finish. During the coloring stage you will really see this mirror take shape. In between steps grab a microfiber towel and apply some of our Pro 50 Eliminator to the wheels. This will dissolve any leftover compound from around the holes. Leave the Pro 50 film on after the secondary stage, this will allow you to see exactly where your polishing line is as well as cleaning all of the green rouge off before moving on to the finishing step.
Pro 50 Wipe down Secondary Cut
Final Finish – 1600-1800rpm Last, grab your white untreated airway or flannel buffing wheel as well as the Blue Moon bar rouge. Again, start from the inside and work out to the edges. This will break down any buffing lines left and blend it all together leaving a flawless finish. If all three steps are done like this, the result should be a metal mirror. It takes a little getting used to, no doubt, but once you have a few wheels under your belt you will be ready to attack bigger jobs like fuel tanks and more! With Zephyr’s easy to use products, the beginner can achieve a professional finish.
Wipe Down aka “seal in that shine” – We are not quite finished yet. Now that we have successfully polished the wheel lets highlight that super shine and seal and protect it. That was a lot of work and gratifying as well, so you want to maximize your shine. Grab a microfiber towel and a bottle of the trucking industries #1 selling metal polish, Zephyr Pro 40. Fold the towel into quarters, that way your fingers don’t poke through and scratch the surface. Apply about a half-dollar size amount of Pro 40 on the towel and wipe the wheel down. Go with the grain and apply nice and even all over the wheel. Let it dry and use a fresh microfiber towel to remove it. This will repel water and road grime that you may catch along the way. Use the Pro 40 metal polish for maintenance thereafter.
Thanks for checking out Iowa80.com and if you have any more polishing questions ask the friendly folks at Iowa 80 or go to www.zephyrpro40.com and @zephyrpolishes on Instagram and Facebook. Special thanks to Kevin Clapp, owner of Texas Premier Polishing out of Lubbock, TX, for his input and the pictures of his quality work.
Be Safe & Shine On!