Chiming in on the aluminum intake refinish quandary. No disrespect to you, CudaChick, you do fantastic work. It's just that I've never seen any method that looks "OEM correct" for bare cast aluminum. Is there is a flat aluminum color powder coat that retains the right texture that might pull it off? I'm not aware of one. Let me know if there is. I'll send my manifold to you.
All the DIY "aluminum" restoration materials never look right and most discolor or fail after some miles are put on the vehicle. I'd opt to clean it with something like Aluminox (made by Orison Marketing, the people who make Evapo- Rust) and the use their protective coating and hope I can keep it clean.
Tommy
Oh no Tommy, no offense is taken at all. What a lot of people don't realize is that powder coating has been around for nearly sixty years now and isn't only available in a few colors anymore. Just my main supplier has over 7,500 to choose from, and custom formulations (to match your sample) in the small chance they don't already manufacture that color.
The one I used on top of that Edelbrock Air Gap up there is my customers' absolute most popular choice to replicate the look of brand new aluminum. It's called "Alien Silver," with lots of fine metal flake that sparkles like diamonds when the sun hits it. On the pictured intake above, it had a base coat of black which changed the silver quite a bit, made it more translucent (almost like an old lacquer paint job), and has a fade-to-black sort of effect on the curves and recesses.
Without a black base coat, Alien Silver looks like this:
Please keep in mind though that all silver, gold, and even some red powders have real metal in them so they are not UV stable on their own; the powder can oxidize over time just like the intake itself, requiring occasional polishing to retain the original look. As a result, all silver and gold powders require a clear topcoat to seal the powder and provide that UV stability. Most of my customers prefer a shiny finish while a few others like the more matte/flat original aluminum look. Just like with colored powders, there are also a variety of clear coats that can be used to ultimately create any look you desire.
As far as the casting defects go, I personally get rid of everything that isn't cosmetically pleasing but again, that's up to my customer. Each is different, just like the projects they're working on.
