I did my tunnel (and anything bare aluminum last year). Started with mothers and elbow grease, moved to mothers and powerball, decided my time is worth more money than that. So went and bought a buffer and went from there.
I don't have pics right now, but here's the process I went thru:
Wet Sand
- 400 Grit to get the big scratches and gouges out
- moved to 600 after that
- then went to 800
I was comtemplating going to 1000 then 2000 (I have all the paper from my body work days), but decided to try and see if the polishing compund and spiral sewn buff would take out the 800 grit scratches. Using Tripoli and a sewn buff did just that, took all the marks from the 800 grit right out. The polishing process with Tripoli prob would have been faster if I went to 1000 then 2000, but I feel it is 6 of one half dozen of the other as far as time went.
From there wash everything really good, you want to get any left over Tripoli compound off the aluminum before the next step.
For the next step (possibly final, depending on how good you want it) use a loose section buff, and White Rouge. This will bring the shine (and remove any fine scratches from the Tripoli) to were you want it (looking like a mirror). For this step, you can go as far as you want, the more you go the more it will shine.
Wash really good again, get all the Rouge off the aluminum again.
You can be done now, if you want. But your already there, so why not a little more.
Replace the buff with another loose section buff (a new one), and go to a Jewlers Rouge, this will bring even more shine out. Once again, go til you are happy with the results.
Wash again, and rock and roll.
I was comtemplating on using a good wax to protect it, but then thought I would see how it "weathered" the winter. Amazingly if you do this process in fills in the pores of the aluminum (that is how you get the polished look), and cleans up the rough surface. Water beads right off it, just as if it were waxed. The other kind of nice factor, is that I noticed less snow build up on the tunnel during riding. And the end of the season (1500 miles), it still ooks good (minus the scratches from boots, the trees, etc). I will touch it up again in a few weeks, and it should look like new again for another season. If you are interested in doing this, go to eastwood.com and you can buy all the stuff necessary (compound, buffs, etc).