Tricks to a perfect 45 degree on rails?

[rotorzoomer]

What are the tips and tricks people are using to ensure a perfect 45 degree angle and what types of methods are people using to polish (Saw a wooden rig on the forum with sand paper) smooth so the bearings make contact on both sides perfectly?

From looking at the finish i did, i think it's more like 42 degrees and the bearings don't make contact properly. I have brand new disks to make the final pass before drilling and painting.

I assume the first issue relates to how perfectly the skate components have been bent but looking for advice on what has worked for my fellow MM builders.

[KenC]

Marco,
I cut a sample piece & tune the angle accordingly.
Grind a sample piece on both side & check with a set square.
You only need to set the correct angle once.

[rotorzoomer]

Thanks Ken, just got the set square out and can clearly see the improvements that need to be made and skate adjustments. Luckily i left enough material to be able to do a final pass?

What did you do to finish the rails...did you polish them or sanding using 240 grit paper?

[KenC]

I did a very light final pass over it & the rail turn out sparkiling. Used a diamond needle file to deburr the edges, did not touch the ground surface at all.
Don't forget to it down with a oil soaked rack to keep it from rusting...

[rotorzoomer]

I was wondering about those burs as well, they do make the bearings jump until they are sanded or cut off.

[KenC]

Always a good practice to remove burrs before they draw blood

[rotorzoomer]

They are actually not that bad, the cutting disks and angle of attack on the angle iron produced a nice smooth finish on a downward cut method, you can definitively feel something is there ever so slightly. I have also use a silky type cloth that catches on anything as a guide to smoothness as well.

Thanks for the tips!