For aluminum, I just put 320 grit sandpaper on my electric vibrator (not 
*THAT* kind of vibrator...) and it leaves a nice swirly pattern. It's very 
easy to find surface imperfections by the blurry ring around them, so just 
sand that area a bit more.

I dont leave bare metal exposed on frontal areas; they get painted then I 
apply laser-printer decals.

A co-worker had a panel made thru frontpanelexpress.com, and he had it 
powder-coated. It was beyond awesome.

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