Many thanks, here we go then...
I'm a Mechanical engineer and have an abundance of patience, definitely required ..
4 x 80 grit wet and dry
4 x 120/180 either is fine
4 x 240/360
4 x 600/800
4 x 1000
1 x glass surface plate, or equivalent surface able to repel/withstand water and abrasives.
1 x tube/can Autosol
Autosol is a fantastic abrasive for steel or plexi, the results are amazing. My first experience with Autosol on plexi was a set of headlights that had crazed on an import supra. I could not believe the result !! But the process of leveling and increasing grains per sheet must be followed.
The amount of paper used and the frequency of change depends entirely on the pressure applied. LET THE PAPER/WATER DO THE WORK.
Even pressure and ONLY forward and backward motion using the FULL length of the sheet, keeping the block in the ONE direction the entire process, place a dot on the protective paper stuck to the underside of the block for orientation. This means NO cross scoring VERY important for polishing.
Plexi will emit a fantastic amount of waste for a remarkably small cut, ignore this waste material ...and the smell... and monitor the depth of the process using the crop circles as a depth indicator. Remove the badge by inserting a 2mm flat blade jewelers driver firmly down one edge then firmly levering upwards, looks great on my case !. I chose not to separate the plexi to perform the work however its up you as to what gives you the best control. The block must be opened at some stage for the jet to be polished also ( just a few rubs on the 1000/1200 looks great !)
I used on average 3 sheets per level of cut, but be sure the 80 grit does its job and takes of 85 - 90 percent of your waste material. This way you can level and adjust any issues before the fine tuning. The 80 grit i used was glass paper and can be used wet or dry.
By the time you reach the 800 grit paper only tiny traces of the circles should remain...if any. You will know your close to finished with the wet and dry when the wet look (water over the surface) is your ideal finished product, time for the Autosol.
Simply find a suitable polishing rag and replicate the action used in sanding this time with your fingers/thumb (ALWAYS THE SAME DIRECTION AS THE INITIAL SANDING) start on one side and gradually moving across in a firm up down motion, a gentle heat from the friction should be felt. Repeat until you see the glass
Total time: 2hrs
Best of luck, not sure i will take orders just yet .... i could definitely be coerced