So I spent a couple hours sanding the playfield in preparation for the hard top yesterday afternoon. Turned out nice, this one had a bit more black dust ground into areas of the playfield I wasn't willing to sand all the way out.
I always get disheartened at the beginning on the 60-grit because the inserts don't feel level at first (Feel humped up even) and it takes quite a bit to sand them flush. If you haven't replaced inserts, replacements are taller and a little wider than the holes they go in. My last post showed me sanding the sides and I also scuff the bottoms so the epoxy has something to grab. I also use my milwaukee rotary tool to clean out the holes. You're usually left with a .02-.05" lip above the playfield.
The playfield art also comes off pretty slow and you go through about 3-6 pads due to the adhesive that's left over from the mylar as well as sanding off the clear coat. I feel the inserts along the way and can feel the little humps and just feel like it will never level out! It does though! Once I get to about 120 or 180 grit I start to get happy .
In general my process is to do passes side to side short ways or long ways with about half a sander overlap. I want to get everything off til there's about a half inch of art around the inserts so I can see which ones are still humped up when I hit just the tops of them (I sand the tops of the inserts in the process as well, not just around them). I work away at the tops of the inserts until I notice the art around them coming off and then I know i'm getting pretty level with the playfield. I also make sure I move from insert to insert to make sure I don't get them too hot. All of this is with 60-80 grit paper at this point. Once I get things fairly even I switch up to 80 grit and start just doing even, overlapping passes. No specific amount, sometimes i'll do 2, sometimes 4. They go relatively quick.
The grits that come in the kit I use are 80 180 220 400 600 800 1000 1500 2000 3000. I have some 60 grit and 120 grit that I added as well, but if you get the kit you can just use the steps it comes with (https://www.amazon.com/gp/product/B0B51GK5Z7/ref=ppx_yo_dt_b_search_asin_title). I ordered an extra set because I was low and thought I ordered one that went up to 10,000 grit and was excited to try that, then realized upon opening it was 400-3000. Oh well, next time!
No clear coat, no wet sanding, just a Dewalt 5" 20v sander. I went through a 9AH 60v FlexVolt battery and 1/4 of another. So probably a couple 5AH 20v would do it.
I did not tape anything on the bottom side of the playfield. When finished I used my little air compressor to blow out each hole and bulb socket as well as the back of the playfield. It really is not that bad. I see people take their time and tape holes and stuff but it's just not worth it if you have a compressor. I taped my first one and I still have to blow it out.
Sorry for the deluge of pictures but wanted to show some detail between steps. Unfortunately I didn't mark each one, but once you get up to about 600-800 grit it starts looking a little shiney on the wood. 1500 is where the inserts start getting really clear and 3000 grit makes it look polished.
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