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We have been talking a little on how rough the surface ought to be to take a rust. I sort of waiver between #240 and #320. #320 will give you as fine a browned surface as you are going to get. In other words if you take two barrels and use #320 on one and take the other to #600. It will be harder to establish rust on the #600 but once you get rust, the surface will be sort of rough and the #320 and #600 will produce a final surface of equal smoothness. With the #240, it is even easier to get a brown rust but the barrel might be slightly more rough although I've used #240 on some guns and I am happy with the results.
The big thing is that damp but not wet rag and a single swipe of the solution on the metal and then that's it. As I said, if you miss an area- don't try to correct with a second swipe, just get it on the next application. And card with a rough cloth and hot water as has been stated.
 
Getting there now. Most of the barrel is now developing that nice brown color. It seems to take a full day to develop. Wondering if as slow as it seems to be, if I'm really doing any good, (or if it's necessary) to re-coat it every 24 hours though, and, if I could let it go 36 or even 48 hours between treatments. That said, I did give it another treatment this morning before I left for work.
 
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