George, guys,
Thank you very much for the info. I'm afraid to jump into the project w/my rotory tool (high speed dremel type), file, and abrasives on my new parts; to get the very soft "melt" that I'm looking for. That is how I "thought" that I might do it, (w/out jigs), originally. Then remove all scratches w/fine polish, reliability test, and have it plated. I'll take your advice and just use a polish wheel and 140 compound. I'll be a very happy camper if this is all it takes.
George, although I plan to practice on some square stock first, do you think that it is very difficult to get a uniform melt with your method? Any particular details are welcome.
Also, is there any benefit to using any particular sized wheel? Should it be sewn cloth, or hard felt?