How can repair file marks be removed from an aluminum propeller?

Removing repair file marks from an aluminum propeller is a delicate process that must prioritize the integrity of the propeller surface. Using fine sandpaper is effective because it allows for a controlled and gentle method of smoothing out the marks without significantly altering the thickness or structural integrity of the propeller.

Fine sandpaper can help to gradually level the surface and blend in the repaired areas to create a uniform finish. It is important to use fine grit to minimize the risk of introducing new scratches or imperfections, which could affect performance or aerodynamics. Proper technique is essential to ensure that the sanding is even and does not create a rough surface that could harm the propeller's efficiency in flight.

The other methods, while they might seem effective, could pose risks. A power sander could remove material too aggressively and lead to an uneven surface. Chemical fillers can obscure the area rather than truly repair or smooth it, and a buffing machine might not effectively address the depth of the filing marks and could potentially create heat that could warp the aluminum. Thus, using fine sandpaper strikes the right balance for effectively removing file marks while preserving the propeller’s structural and aerodynamic properties.