heres one I did earlier.
http://img2.photobucket.com/albums/v11/macuser/P4030009.jpghttp://img2.photobucket.com/albums/v11/macuser/eb643e98.jpghttp://img2.photobucket.com/albums/v11/macuser/ggg.jpgFirst you have to take the manifold off but in my case I was doing the head gasket so it had to come off anyway.
You use the roughest sanding paper you can get (I used 600 grade) and take all the rough casting 'dimples' away so theres no low spots. you have to use your hands as you have to follow the contours of the mani. dont bother with the 'inbetween' areas as it looks good with the contrast in textures - also I left the sides rough. I used an electric sander but dust went everywhere (not sure about the health aspects of breathing this in so think about that if you have one !) There were really low spots so I had to really go to town on those bits.
When its smooth you can use finer paper and really work at it till its smooth. It may take hours and your hands will start bleeding. I did mine in stages - a few hours a day but I did the top part as well which was really rough and harder than the 'curvy' bits.
Use 1200 grade emery paper eventually (not sure if there is 1500 but that would be better) and sand it wet to get it smooth as possible. It will look pretty good at this stage; a sort of brushed aluminium effort but the best bit is when you polish it with crome or metal polish - it suddenly goes all shiny. You will still see lots of little scratches in it though; no problem just rub it gently with finest emery cloth again with water then polish again. You will eventually get a mirror finish but it takes along time and lots of effort - this can be done poorly or well depending on effort put in.
