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I switched to Aerolite UP4145 One Shot and it’s been very good. Only problem is that the smallest size is 1Kg.

Yes, that’s what I’d do first. I’ve done this many times. Unlike acid it doesn’t etch the surface of the metal. After that I’d use abrasive pads, the green supermarket ones work just fine.

Just to add, ordinary bolts or threaded rod isn’t the best solution. I’d probably use socket shoulder screws. I would also drill, then ream any holes to size.

Newbie on here, though I’ve been around some other forums a bit. I dabble in a variety of materials including wood so thought I’d join up. No projects on the go at the moment and it’s starting to get cold in the shed so I don’t expect I’ll be out there very much in the coming weeks. Looking...