How to Deburr a Titanium Exhaust Tip by Hand (60–120)

Titanium exhaust tips can have sharp cut edges and burrs from trimming or welding. Deburring isn’t about making it mirror-polished—it’s about removing the razor edge safely, then leaving a smooth, uniform edge that won’t slice fingers or snag microfiber towels.

Why Sanding Matters

A controlled grit sequence removes discoloration/oxidation without gouging the base metal. It also creates a predictable scratch pattern—important for primer adhesion, powder coat bonding, or a clean brushed appearance.

Tools

• Safety glasses and a dust mask (metal dust)
• Gloves (especially when deburring edges)
• Sanding block or a small backing pad (for flat areas)
• Clean rag + degreaser/isopropyl alcohol for wipe-downs
• Painter’s tape (to protect adjacent surfaces)
• Optional: spray bottle with water for wet sanding on finer grits

Recommended Grit Sequence

• 60 grit
• 80 grit
• 100 grit
• 120 grit

Step-by-Step

1. Secure the part. Hold the tip/fitting so it can’t slip while you work the edge.
2. Break the edge with 60 grit. Use short strokes to remove the sharp burr—focus only on the edge, not the whole face.
3. Smooth with 80 grit. Blend the 60-grit bite marks and round the edge slightly for safety.
4. Refine with 100 grit. Even out the scratch pattern and remove any remaining “hooks” you can feel with a fingernail.
5. Finish with 120 grit. Light pressure, longer strokes. The edge should feel smooth and uniform all the way around.
6. Clean and inspect. Wipe off dust and run a fingertip lightly along the edge to confirm it’s consistent.

Special Cases

If the tip is thin-wall, avoid aggressive pressure that can oval the edge. For tight curves, tear the sheet into smaller strips and wrap them around a dowel or socket for control.

Pro Tips

• Don’t skip grits. Each step is faster if you fully remove the previous grit’s scratches before moving on.
• Use a backing block when you can. It keeps the surface flatter and prevents finger-grooves.
• Light pressure wins. Pressing hard creates uneven scratches and heats the metal faster.
• Wipe often. Residue can hide scratches and make you jump grits too early.

Aftercare

• Wipe with isopropyl alcohol to remove sanding residue.
• Keep bare metal dry until it’s painted/coated/sealed.
• If you’re coating, avoid touching the surface with bare hands after final cleaning.

FAQs

• Wet or dry? These sheets work in wet or dry sanding. Wet sanding can reduce loading on finer grits.
• When should I stop? Stop when the scratch pattern is uniform for your intended finish (primer/powder/brushed/bare).
• How do I avoid random scratches? Keep your sanding direction consistent on the final grit and clean the surface before inspecting.

Watch & Learn

If you want to follow the same progression on your next project, keep these grits ready: 60 Grit (25 Pack), 80 Grit (25 Pack), 100 Grit (25 Pack).

Work steadily, inspect often, and aim for a consistent scratch pattern—once it’s uniform, your finish (paint, powder coat, or brushed metal) will look much more intentional.