Ever wondered how professionals are able to consistently get a flawless finish on metal surfaces? This all comes down to proper metal buffing. Whether you're restoring classic car parts or finishing custom metalwork, mastering the art of metal buffing can transform your projects from good to great. In this guide, we’re giving you the secrets that will help you get professional-grade metal finishes.

Table of Contents

Understanding Metal Buffing: The Basics

What is Metal Buffing and Why is it Important?

Metal buffing is a finishing process that smooths out imperfections on metal surfaces to create a polished, glossy look. At a microscopic level, buffing works by using abrasive compounds and friction to remove a fine layer of the metal surface. The abrasive particles in the buffing compound cut away tiny imperfections and scratches, while the heat generated from friction helps to smooth out the metal even further.

Buffing not only adds to the aesthetics of the metal, but it also increases its resistance to corrosion, preserving and enhancing the longevity of it.

Buffing is broken down into two main stages, cut buffing and color buffing:

1. Cut buffing is the first stage where you’ll use an aggressive buffing compound and a stiffer buffing wheel (made of materials like sisal) to eliminate polishing lines and other small imperfections.
2. The next step is color buffing , which gives you the perfect shine. It uses less aggressive compounds and softer wheels to erase any remaining small lines that cut buffing left behind.

Buffing vs. Polishing: What’s the Difference?

Buffing and polishing are often used interchangeably, but they are different parts of the finishing process. Think of polishing as the prep work, and buffing as putting on the final touches. Polishing is an earlier process that uses abrasives to remove scratches. Buffing focuses on creating a high-gloss shine, often done after a surface is polished.

Below are some of the most significant differences when comparing buffing vs. polishing:

Further Reading: For a deeper dive into the differences and when to use each method, check out our detailed article: What's the Difference: Buffing vs Polishing

Essential Tools for Professional Results

Every craftsperson needs the right tools. Here's what you'll want in your toolbox:

• Buffing Wheels: Different stages of buffing require specific types of wheels, such as sisal, cotton, airway, or buffing drums.
• Buffing Compounds: These substances contain the abrasives needed for smoothing and shining metal surfaces.
• Power Tools: Tools like angle grinders and bench grinders provide the necessary speed and power for effective buffing.
• Safety Gear: Protective equipment keeps you from unfortunate injuries.

In a later section, we'll guide you through selecting the right equipment based on your project's needs.

Metal Buffing Tips

Here's what separates amateur work from professional results:

1. Preparation Is Everything - Starting with a clean, well-prepared surface sets the foundation for a pro level finish.
2. Use the Right Tools for Success - Selecting appropriate buffing wheels, compounds, and equipment is crucial for optimal results.
3. Technique Matters - Proper application techniques (including pressure, angle, and movement) influence the quality of the finish.
4. Maintain Your Equipment During Buffing -Keeping your tools and workspace in good condition ensures consistent performance.
5. Ensure Post-Buffing Care for Long-Lasting Results - Final steps like cleaning and protecting the surface help preserve the finish.
6. Safety First (even though we listed it last) - Always prioritize safety by wearing protective gear and following safe operating procedures.

In the following sections we’ll go deeper into each of these areas.

Preparation Before Buffing

Clean the Metal Surface

Always start with a clean and dry surface. Dirt or grease can ruin the buffing process by embedding itself into the metal, causing scratches and imperfections.

Be Mindful of Metal Type

Different metals require different techniques and buffing tools (more on tools later). For example:

Inspect the Surface

Look for any deep scratches that weren’t addressed before beginning.

Gather the Right Tools and Materials

Before you begin, gather all your tools:

• Buffing Wheels/Drums and Compounds: Select the appropriate wheels and compounds based on the metal type and desired finish.
• Power Tools: Use compatible power tools such as polishers, angle grinders, or bench grinders with appropriate attachments.
• Protective Gear: Make sure you have the appropriate PPE ready to go such as safety glasses, gloves, dust mask, hearing protection, and protective clothing.

Selecting the Right Equipment

Choose the Right Buffing Wheels and/or Drums

• Stitched Sisal Buffing Wheels : Stiff, woven fibers that are used for aggressive cutting.
  • Best For: Removing heavy oxidation and scratches in the cut buffing stage.
  • Product Recommendation: 8” x 3/4" Arbor - 1/4” Spiral Sewn Sisal Buffing Wheel - tight 1/4" spiral stitch pattern increases stiffness, allowing you to apply greater pressure for faster removal of deep scratches and heavy oxidation.

• Muslin Cotton Buffing Wheels
  • Spiral Sewn Cotton Wheels: Medium firmness for general-purpose buffing.
    • Best For: Intermediate stages and color buffing.
    • Product Recommendation: 6” Spiral Sewn Cotton Buffing Wheel - spiral sewn pattern offers just the right stiffness for smoothing surfaces after cutting while still being flexible enough to contour to your workpiece.
  • Loose Cotton Wheels: Soft wheels without tight stitching.
    • Best For: Final finishing to achieve a mirror-like shine.
    • Product Recommendation: 60 Ply 6” Loose Cotton Buffing Wheel - Gentle on surfaces with a flexible surface that adapts to the contours of your workpiece, ideal for polishing intricate designs and detailed metalwork.

• Airway Buffing Wheels
  • Description: Buffing wheels with a pleated design (airway) that allows for better airflow, reducing heat buildup during use.
  • Best For: Both cut buffing and color buffing , depending on the material and compound used.
  • Product Recommendation: 14” Blue Airway Buffing Wheel - multiple layers of cotton provide a larger surface area and longer life, reducing the need for frequent wheel changes during big projects.

• Buffing Drums: Cylindrical wheels designed for larger surfaces and hard-to-reach areas.
  • Best For: Efficient buffing of extensive workpieces.
  • Compatible Tools: Burnishing machines, handheld drum sanders, surface conditioning tools, contour grinders, and linear grinders.
  • Product Recommendations:
    • 4.5" x 4" Spiral Sewn Buffing Drum - Ideal for aggressive cutting on large surfaces.
    • 4" x 4" Wool Flap Wheel Buffing Drum - Perfect for final finishing with a soft touch.

Choose the Right Buffing Compounds

Buffing and polishing compounds are typically sold in a bar shape that is made up of a waxy or greasy substance that contains small abrasive grains. These bars come in different colors which depict a different level of coarseness and material compatibility.

• Black Emery aka Black Magic -
  • Recommended for: Heavy cutting action to remove surface imperfections, rust, and scale during the cut buffing stage.
  • Metals to use on: steel, stainless steel, brass, copper, cast iron, and tin plate
  • Pair with: sisal wheel, blue airway buffing wheel

• Gray Buffing Compound -
  • Recommended for: Prepping non-ferrous metals before color buffing; provides intermediate cutting action.
  • Metals to use on: aluminum, zinc, copper, lead, tin, and other non-ferrous metals
  • Pair with: sisal buffing wheel, blue airway buffing wheel

• Brown Tripoli -
  • Recommended for: Milder cutting, polishing, and scratch removal in the intermediate stages.
  • Metals to use on: aluminum, brass, copper, and other soft ferrous and non-ferrous metals
  • Pair with: yellow airway buffing wheel , spiral sewn buffing wheel

• White Rouge aka White Diamond Polishing Compound -
  • Recommended for: Final polishing to achieve a high-gloss finish on both ferrous and non-ferrous metals.
  • Metals to use on: Soft and hard ferrous and non-ferrous metals, including aluminum
  • Pair with: spiral sewn or loose cotton buffing wheel, untreated white airway buffs , white domet flannel airway buffing wheel

• Green Rouge - 
  • Recommended for: Polishing metals for a refined finish.
  • Metals to use on: Brass, copper, iron, steel, nickel, platinum, aluminum, and stainless steel
  • Pair with: loose cotton buffing wheel, untreated white airway buffs, white domet flannel airway buffing wheel

• Red Jewelers Rouge -
  • Recommended for: Final stage polishing of soft non-ferrous and precious metals; produces a brilliant shine.
  • Metals to use on: Gold, silver, brass, copper, and other precious metals
  • Pair with : untreated domet flannel buffing wheels, loose muslin buffing wheel

Buffing and Polishing Kits

If you’re looking for a convenient way to get started, our buffing and polishing kits have all the necessary buffing wheels and compounds tailored for specific metals. These kits simplify the selection process by providing compatible buffs and compounds designed to work together effectively.

Available Kits:

Aluminum Buffing and Polishing Kit

• Ideal For: Aluminum surfaces; also effective on copper, brass, and other soft, non-ferrous metals.
• Includes:
  • Step 1: Yellow Mill Treated Airway Buff (8") + Gray Metal Buffing Compound
  • Step 2: White Untreated Airway Buff (8") + Brown Tripoli Buffing Compound
  • Step 3: White Domet Flannel Airway Buff (8") + White Rouge Polishing Compound

• Applications: Ideal for polishing trailers, boats, rims, exhausts, bumpers, and other aluminum accessories.

Stainless Steel Buffing and Polishing Kit

• Ideal For: Stainless steel surfaces; also suitable for other hard metals.
• Includes:
  • Step 1: Blue Mill Treated Airway Buff (8") + Black Emery Buffing Compound
  • Step 2: Yellow Mill Treated Airway Buff (8") + Brown Tripoli Buffing Compound
  • Step 3: White Untreated Airway Buff (8") + Green Rouge Buffing Compound

• Applications: Perfect for buffing rims, exhaust pipes, bumpers, and stainless steel items.

Chrome Buffing and Polishing Kit

• Ideal For: Chrome surfaces; also effective on other plated metals.
• Includes:
  • Step 1: Blue Mill Treated Airway Buff (8") + Black Emery Buffing Compound
  • Step 2: Yellow Mill Treated Airway Buff (8") + Brown Tripoli Buffing Compound
  • Step 3: White Untreated Airway Buff (8") + White Rouge Polishing Compound

• Applications: Ideal for restoring shine to rims, exhausts, bumpers, and chrome accessories.

Power Tools Compatibility

Use compatible power tools like polishers, angle grinders, bench grinders, and surface conditioning tools with buffing attachments to make the job easier. Always match the buffing wheels and compounds to your specific tool to get the best results and avoid accidents.

• Check Tool Specs: Always check to make sure that the arbor (spindle) size of your power tool is compatible with your buffing wheel.
• Use Adapters or Bushings: If the arbor size doesn't match, you can use adapters or reducing bushings to fit the buffing wheel onto your tool securely. An angle grinder extension shaft can give you some extra clearance to fit a wheel.
• Consider Wheel Thickness: Ensure that the thickness of the wheel is suitable for your tool's spindle length and that it can be safely mounted with appropriate flanges or washers. Power Tool Strength: Larger diameter wheels (e.g., 10", 14") require tools with sufficient power to maintain optimal RPMs without bogging down.

Buffing Techniques

Apply Compound to the Wheel, Not the Workpiece

When applying buffing compound, always apply it directly to the rotating buffing wheel rather than the workpiece. Why?

• Even Distribution: Applying the compound to the wheel ensures it spreads evenly across the wheel's surface, providing consistent buffing action.
• Prevents Clumping: If you apply compound to the workpiece, it can lead to clumps of compound that may scratch or mar the surface.
• Efficient Use of Compound: This method reduces waste by using only the necessary amount of compound.

Use the Right Technique

Maintain a consistent angle, use overlapping strokes , apply light pressure, and keep the buffing wheel moving to avoid overheating or creating uneven finishes.

Practice and Testing

Practice on scrap metal or on a small hidden part of the workpiece before proceeding with the entire surface. This way you can get comfortable with the tools and to make sure the metal reacts to the compound and wheel as you expected.

Buff in Sections and with the Grain

Buffing in small sections will help you make sure you get a thorough coverage of the entire surface.

Always buff in the direction of the metal grain to prevent scratches and enhance the final appearance.

Maintenance During Buffing

Inspect Your Work Frequently

Stop periodically to inspect your work so you can catch any problems and make corrections before it’s too late. Use bright, even lighting that will reveal any imperfections. Look for signs of swirl marks, uneven shine, or discoloration.

Avoid Cross-Contamination

Use separate wheels for different compounds to avoid cross-contamination. Rake the buffing wheel frequently to keep it effective and avoid clogging. After finishing with one compound, use a clean cloth to wipe down the metal surface before applying a different compound.

Keep the Work Area Clean

Dust, debris, or leftover compounds can easily get caught in the buffing wheel and can scratch your workpiece or lead to an uneven finish. Regularly sweep your workspace, wipe down surfaces, and keep your tools organized.

Control Heat Build-Up

Buffing generates friction. This friction can quickly cause heat to build up which could warp or discolor the metal or break down the buffing compound too fast. Using the proper techniques mentioned above (light pressure, keeping the wheel moving) will help mitigate the heat. If you notice the metal getting too hot, stop and let it cool down before continuing.

Post-Buffing Care

Finish with a Clean Cloth

After buffing, it's important to remove any residual compounds to bring out the shine. Use soft and non-abrasive cloths like microfiber cloths.

Apply Sealants or Waxes

To protect the finish, apply a wax or sealant. This will help preserve the shine and prevent oxidation.

Safety Measures

Always wear safety gear, including safety glasses and gloves. Secure smaller workpieces with clamps to avoid accidents, and work in a well-ventilated area to prevent inhalation of dust or fumes.

Frequently Asked Questions (FAQs)

What is the best buffing compound for stainless steel?

Use Black Emery Compound for initial cutting to remove imperfections. Follow with Brown Tripoli for smoothing, and finish with White Rouge or Green Rouge to achieve a high-gloss shine. Pair each compound with the appropriate buffing wheel for optimal results.

Is it necessary to use different buffing wheels for each compound?

100% yes. This prevents cross-contamination and yields a cleaner finish.

How do I prevent swirl marks?

• Use Proper Technique: Buff with consistent pressure and follow the metal's grain.
• Choose the Right Equipment: Use soft buffing wheels and fine compounds for final polishing.
• Keep Wheels Clean: Regularly rake wheels to remove debris.
• Avoid Cross-Contamination: Use separate wheels for different compounds.
• Inspect Frequently: Check your work under good lighting to catch issues early.

What's the difference between using a bench grinder and an angle grinder for buffing?

• Bench Grinder: Stationary tool offering stability and consistent power; ideal for smaller, handheld items.
• Angle Grinder: Portable and versatile; better for larger or fixed workpieces but requires more control and may have less precise speed settings.

Buffing for a Professional-Grade Finish

Mastering metal buffing isn't just about having the right tools—it's about patience, technique, and attention to detail. Start with clean metal, work methodically through each stage, and maintain your equipment. With practice and the proper supplies, you'll achieve mirror finishes that rival professional results.

Need help selecting the right buffing supplies for your project? The team at Empire Abrasives is here to assist you. Check out our complete selection of professional-grade buffing wheels, compounds, and kits, or contact us for personalized recommendations.

Ready to elevate your metalworking projects? Explore our premium buffing products today.