Orbital Buffer



The Flex XC 3401 VRG (7.5 Amp electric motor) would be the best option prior to stepping-up to a rotary polisher (Rotary 101, if you will); this tool was made for paint correction (used by EU car manufacturers, much like the Cyclo is in the for US production line paint correction) it is far superior in its paint correction abilities than a Porter Cable 7424XP (PC) however it will not make paint corrections as fast or as thoroughly as a rotary polisher.

Due to its forced rotation its more powerful yet totally safe, removes light to heavy swirls, applies polishes, glazes, sealants, waxes, etc and has the best balance of power and totally safe polishing



Like all tools there is a learning curve with it, so first gain experience on a paint surface that doesn’t matter i.e. a scrap panel, practice until you feel confident enough in its use and capabilities to use it on your own vehicle. The immediate future in automotive clear coat paint is something very similar to CeramiClear i.e. very hard.



The Flex has the ability to correct this type of hard paint, whereas a PC requires a quite a few passes to correct them, and also struggles to breakdown diminishing abrasives (something else that car care products are going over too) as it doesn`t provide sufficient friction)



Porter-Cable 7424 XP (4.5 Amp electric motor) - a US power tool company, Porter-Cable established in 1914, began manufacturing an electrically operated Variable-Speed Random-Orbit Sander in the 1990s for the wood-working industry, now one of the most popular tools used by professional and enthusiast automotive detailers alike. Often known by the companies initials PC (Porter-Cable) but also called a ROB (random orbital buffer) or DA (duel action) polisher



Excellent value, safe for novices, removes light to moderate swirls, applies polishes, glazes, sealants, waxes, etc.

The Porter Cable is the perfect buffer for new detailers. The random orbital buffer gets its name from the action of the buffer (or polishing head) This operates by the shaft rotating and spinning the back plate on an orbit radius or an eccentric offset (or throw) of 5/32-inch as opposed to a revolution on a direct-drive system, and within this eccentric orbit it also rotates in very small circles



The random orbital buffer operates with a variable speed, user adjustable, from 2,500 – 6,000 orbits per minute. (Speed # 1-5 also have a half speed setting) The application of detailing products with a random orbital has the advantage of ensuring an even pressure and constant contact speed, mimicking free hand motion but at a far greater speed.



By allowing the weight and the random motion of the machine do the work, thus ensuring that the product is applied in a thin even layer, and will allow products to get embedded deeper into the paint film surface`s porosity.



Apply wax or polish at speed 3, remove polish at speed 5-5.5 (I would not advice using speed 6 for long periods due to heat generated to the Velcro® on the backing plate may cause delaminating of the glue that adheres the Velcro® to the foam pad. A random orbital buffer won`t leave swirl or buffer marks on your paint.



That`s because it doesn`t spin like a rotary nor does it have the rotaries speed or power. The elliptical motion mimics hand movements, only much, much faster.



The random orbital buffer gets its name from the action of the buffer (or polishing head) This operates by the shaft rotating and spinning the back plate on an orbit radius or an eccentric offset (or throw) of 5/32-inch as opposed to a revolution on a direct-drive system, and within this eccentric orbit it also rotates in very small circles After using a high-speed rotary polisher use a random orbital buffer at speed #3 and Zaino Z-AIO, which will provide an extra depth and added gloss



Pros- the random orbital buffer is manufactured as a sanding machine, but can be adapted as a very safe polishing machine, as it lacks the power to burn paint. It is very easy to use and is ideal for very minor paint correction and the application of car care products



Cons- it lacks the power to produce the kinetic (or dynamic) friction required to breakdown the diminishing abrasives in polishes designed for hard clear coats and / or paint correction / renovation, although it could be used for this purpose utilizing 4-inch foam pads to increase surface friction / heat it is very time consuming



Alternative random orbital buffers – Groit’s 6-inch Orbital Polisher, VRG, Flex XC 3401, Bosch Gex -150 Turbo, Festool Rotex - RO125, Makita BO6040 Polisher (alternate between circular or dual-action modes)



Griot`s Garage 6 inch Random Orbital Polisher



A powerful 7 amp (850 watt) motor with low-end torque for low speed polishing for better results, a wider 5/16 - inch (8mm) diameter offset orbit for faster polishing With the Griot`s Garage system, a safer and easier way to remove swirl marks, fine scratches, and apply a protective coating to your paint.



Griot`s Garage 3" Mini Polisher



• 2.0 AMP

• 240 Watt Motor

• Approx $ 90



Porter Cable 7424XP Dual Action Polisher



The polisher is capable of working at faster speeds than the original 7424, which enables the 7424XP to remove more paint imperfections. This more aggressive removal allows you to use the Porter Cable 7424XP Dual Action Polisher for tougher detailing jobs and get optimum results.

• 4.5 –Amp, 450-Watt motor

• 45dB A noise level speed 6

• 2,500 – 6,800 Orbits Per Minute (OPM)

• Variable Speed

• 5/16"(8mm) offset

• Approx $120



Cyclo Polisher



The Cyclo Polisher is the only dual-head polisher on the market. Both heads move in an orbital motion, counter clockwise. The idea is to simulate hand polishing but at a much faster rate. Going over a scratch or swirl with both heads ensures that you are attacking it from all sides, so to speak.



• 115 Volts, 60 Hertz, 220 Watts

• Motor: alternating current, semi-enclosed 24-bar commutator

• Speed: 3000 orbits per minute (OPM)

• Output: 1/3 H.P. (0.25 KW

• Weight: 6.5 lb. (2.9 kg)

• Head Rotation/Diameter: clockwise/4-inch

• Housing: heavy-duty cast aluminium, double insulated

• Approx US$ 300



Flex XC3401V Dual Action Polisher (with forced rotation)



The orbital rotation of this innovative polisher simulates the circular movement of the human hand while polishing. The head also rotates, creating more action than typical orbital’s.

Maximum polishing pad diameter - 6.5 inches (160 mm)



• Velcro pad - 6- inches (150 mm)

• Motor Amps 7.5

• Speed without load – 3,200 - 9,600 OPM plus 160 - 480 RPM direct rotation

• Orbit (stroke length or offset) - 5/16 - inches (8mm)

• Power input - 900 Watt

• Power output - 590 Watt

• Weight - 5.73 lbs (2.60 kg)

• Approx $300



Metabo SXE400 Random Orbital



• Sanding pad size 3 1/8 –inch diameter

• Orbits per minute 5,000-10,000

• Thumbwheel for continuous variation of speed

• Variospeed full-wave electronic speed control

• Orbit size 1/8 offset

• Amps 2.0

• Tool weight 3.3 lbs.



Rotary Polishers



A high-speed rotary polishing machine Porter-Cable 7428, Metabo PE12-175, Flex K603VVB, Makita 9227C, DeWalt 849, Hitachi SP18VAH and etc, which are all fine machines, that have a direct-drive with selectable speed control that maintains a constant speed under varying loads conditions.

Used mainly by body repair / paint shops or very experienced detailers to rectify more serious paint film surface imperfections using a Velcro baking plate, foam or wool pads of varying coarseness and an abrasive compound or polish to remove swirl marks, scratches and paint defects, using their high (revolution) speed and friction (heat) to enable compounds to abrade the paint film surface that require more power /speed than a random orbital buffer can provide.



Safety hazards - always remember that you are using a power tool that must be given the respect it deserves. As with running any power tool, read the manual and understand how to safely operate it and what its limits are and the potential dangers that could result by using it. Never forget for a moment that given the right conditions, it could kick back and jump out of your hands. Always wear safety glasses and hearing protection.



Also, polishing compounds often contain silicates that become airborne in the polishing process, inhaled they could represent real health concerns. Read the safety data sheets and follow safety directions. Personally, I almost always wear glasses, hearing protection, a quality dust filter or mask and a buffing apron when buffing. (See also “Rotary Polisher Usage Tips “article) [/COLOR]



FLEX PE14-2-150 Lightweight Rotary - (10 amp /motor with a no-load speed range of 600-2100 rpm) lighter (5.5 Lbs) more agile, and very easy to control than any other rotary polisher it’s well adapted for newcomers to the hobby, starts out at 400 RPM via the trigger and sets at 600 RPM with the trigger lock engaged for the low speed.



Ergonomically designed shape to give your hand and wrist a comfortable place to rest during operation with a lightweight body (5.6 pounds) the front of the polisher is perfectly curved to fit the user`s hand and coated in rubber for superior comfort. The spindle lock mechanism is located behind the hump you see above so you cannot accidentally press it. This Rotary Polisher is built to be light, agile, and fast - perfect for professional detailers who spend hours behind a buffer (approx $380 US)



Notes



1. Warning: Always use ground fault protection interruption (GFPI) when using any electrical device around water



2. Porter Cable 7424 random orbital polisher; the limiting factor to pad size is the actual power of the machine. Using larger pads on these machines actually reduces the amount of polishing power due to the surface resistance of the pad, which will cause the motor to slow down or stall. Conversely using a smaller pad will increase the power available by reducing the surface resistance by concentrating motor power on a smaller area.



3. Dual-Action Forced Rotation or Rotary Polisher: A larger pad has a greater abrasive ability used on a machine that has a forced rotation because motor power (torque) is not a limiting factor the larger the pad, the greater the pad velocity at an identical speed.



4. If you are using an orbital on a ‘hard’ clear coat (i.e. Audi, BMW Corvette, GM, VW, etc) use a 5-inch Lake County (LC) closed cell structure (CCS) foam pad and a 4.5-inch baking plate



5. One of the better polishes I`ve found that will reduce imperfections and finish down the furthest is Menzerna, these polishes are foam pad ‘dependant’ as far as its paint correction abilities are concerned. I’d recommend a two level foam pad / polish system to really bring out the paint.



6. Start with PO 106FA and a primed LC Orange foam pad and follow with white foam. Menzerna polishes will not finish up dry, but will always have a hazy film to them; use them until the haze changes from the polish colour to almost transparent



7. Use a single ‘line’ of polish / compound or three small dots on a rotary, use an X on a random orbital



8. Apply enough pressure (approx 15 pounds force; 20 + pounds force will stall the motor) a foam pads should be compressed approx 50%) so that the pad still oscillates at full speed, but by applying any more the machine begins to stall, and then back off the pressure very slightly



Dodo Juice Spin Doctor Lightweight Rotary, - the Spin Doctor is a compact and lightweight (1.8kg bare) machine with a powerful 1100W motor and digital speed control. This means a digital LCD display shows your speed to the nearest 100rpm and you can accurately adjust your polishing speed from 1000-3000rpm at the touch of a button. Comes with a side handle, a long, long 4m lead, a spare brush set and a hard carry case and it also has a one year warranty and CE marking.



Note that it is M14 fitment and UK spec (3 pin plug, 220-240v).





• Digital speed control with an LCD display shows the machine speed, from 1000-3000rpm in 100rpm increments. You adjust it via a simple and convenient press of a button (+ for up and - for down). This is a first for the UK market as far as we are aware and allows for accurate and easy adjustment of speed when polishing.

• Lightweight 1100w lightweight and compact machine, weighing just 1.8kg "bare" i.e. without side handle, or 2.0kg exactly with the side handle (as most people would use it). For comparison, a Chicago/Milwaukee weighs 2.2kg with the handle and the Kestrel is 2.8kg with the handle.

• Spare brush set each machine comes with a spare set of brushes to help prolong its life before servicing is required.

• Hard carry case to store it in when not in use, impact resistant.



Rotary Polisher Comparison



A high-speed polishing machine, the high-end machines have a direct-drive with selectable electronic speed control that maintains a constant speed under varying loads conditions regardless of pressure applied.

• Porter-Cable 7428 - reliable , 10-amp motor, variable speed 0- 3,000 RPM, 9 Lbs weight

• Metabo PE12-175 – ergonomically sound , on / off switch, feathering variable speed 700 – 2200 RPM, 10-amp motor, 6 Lbs weight

• Makita 9227C –a reliable workhorse, ‘soft start’ trigger switch and variable speed 600-3000 RPM, 76 dB A at 1500 RPM, 10-amp motor, 6 Lbs weight

• DeWalt DW849– a reliable machine, 8 Lbs weight, 1000 – 3000 RPM, 8-amp motor , 84 dB A at 1500 rpm

• The FLEX L3403VRG - a lightweight polisher (5lbs) 1100-3700 RPM -7.5 amp motor

• Flex LK603VVB (6.5 Lbs) 1200-3000 RPM- 10 Amp -Tool Fixture 5/8 – 11

• FLEX PE14-2-150 (5.5 Lbs) 600 – 2100 RPM – 10 amp motor



Nascent polisher users



• Remove all rings, watches, bracelets, belts and other items that will scratch your paint.

• Ensure a clean surface before polishing, wash, clay and then use a chemical paint cleaner

• Be very patient; strive for but don’t expect instant professional results, it takes practice.

• Use tape to protect any areas that you don’t want polish residue in

• Use quality inspection (Brinkman) / general task lighting (dual 500w halogen setup)

• Use the correct pad / polish combination to remove the surface defects

• The Optimum or Prima line of polishes have a good working time and are ideal for inexperienced machine polishers

• Always ensure that you start / stop the machine while it’s on the paint surface

• Don`t over use polish; start with an X or a circle on the outside of the foam.

• After the first panel use 2 or 3 pea sized drops for each polishing area

• Limit your polishing area to 12 x 12-inch, a smaller area will allow the lubricants in the polish to fully work and protect from dry-buffing, once you are more accustomed to using to using a machine polisher you can increase this area to 18 x 18-inch

• Use a polishing pad utilizing a soft less dense foam (70 PPI) i.e. LC White with a light abrasive cutting action for the application of micro-fine polishes

• Overlap each polishing area to ensure complete coverage

• Move the across the surface at about 2-inch per second (this is very slow but a good novice practice speed)

• Apply enough pressure on the machine to compress the pad 50% (this equates to approx 15 Lbs) if you’re not sure apply pressure until the machine almost stalls and then back-off a little

• Use a 1:1 isopropyl alcohol / distilled water wipe-down to inspect your work.



GFCI and Extension Cord



Extension cord sizes are specific for different types of tools. The amperage flowing through an extension cord can ruin a tool. It is important to choose extension cords that are proper for the kind of tool you will be using. Extension cord selection is biased on two main principles. First, the cable should be able to carry the current load imposed on it without overheating. It should be able to do this in the most extreme conditions of temperature it will encounter during its working life. Second, it should offer sufficiently sound earthing to (a) limit the voltage to which people are exposed to a safe level and (b) allow the fault current to trip the fuse or MCB in a short time.



To meet these requirements requires consideration of the circuit load current (amps) a reasonable voltage drop (5%) cable thickness and length and the over-current protection device. Generally, current delivered to static loads is lowered by increased extension cord length(R) Resistance goes up; current (amps) goes down (I = E / R = Current x Resistance).



Wire Resistance and Voltage Drop Calculator - Stealth 316 - Wire Resistance and Voltage Drop Calculator



Cable Gauge



• 16 American Wire Gauge (AWG) up to 100 feet long will adequately handle loads up to 10 amps.

• 14(AWG) Gauge between 0 and 50 feet long will adequately handle loads between 10 and 15 amps.

• 12 (AWG) Gauge if the electrical load is between 10 and 15 amps and the length of the cord is 50 to 100 feet



1. Prime Wire & Cable Duplex GFCI (Ground Fault Indicator) - Junction Box with 6-Ft. Cord, Model# GF200806 Portable GFCI duplex receptacle detects power leaks and shuts off electricity in less than a second to prevent shock. Test and reset buttons Tough jobsite box with 6-ft. 12/3 SJTW power cord UL listed, meets OSHA standards.



2. Prime Wire & Cable extension - 12/3 Neon Power Cord — Blue, Model# NS514830 Bright NEON extension cord stands out for easy identification. 12 Gauge, SJTW, 3 prong cord features super-flexible vinyl jacket with a cold temperature rating of -31°F. LIGHTED connector indicates when power is on. Cord is water and flame resistant and rated at 15 amps, 125V, 1875 watts, UL listed and meets OSHA standards – Northern Tool Co