Double Trouble,

Send me an email off line and I will send you a copy of the Burris catalog that has my rifle on the cover. Include your phone number in the email and I will call you to discuss the bluing process.

I use a series of files. The cut will depend on how much material I want to remove. The key is not to let the file load up and gouge the metal. As far as the flats are concerned. It takes time to do it correctly and yes you will have a series of microflats on the barrel that when done correctly become round. Its like taking an octagon barrel and transitioning it to round. For every flat it needs to be recut on the mill at least 6 passes to transition to a semi round profile. The more passes the rounder it becomes. You will get to the point of diminishing returns and only hand work is required.

As far as barrel spinners go. Its possible to get a very good finish depending on how the barrel is held in relationship to the belt sander. If you polish the barrel at a direct 90 degree angle to the belt the chances of ripples is super high. If the barrel is polished almost in line with the belt sander the ripple factor is reduced to almost zero. Again it takes time to get it right but its not hard to learn.

If a super mirror bright finish is what you want do this.
Use a barrel spinner and go up to 600 grit that is worn slap out. This will create about a 1000 grit finish or close. Then use a high speed polishing disc with micro polishing compound. This will bring it up to a mirror finish. Keep in mind the speed of the disc will really polish the barrel. If there are ANY fine scratches that you did not remove in the beginning stages they will ALL show up. The bluing is not the hard part its the prep work. A mirror finish will not be as durable as a lower polished finish because the steel is much flatter. If the gun is rubbed against something the chances are greater that the finish will come off. The results can be really spectacular when done correctly. Anyone can better the best factory bluing because they do it in a production manner and do not have the time to put in a bit of TLC.