OK, thanks guys. I ended up getting the really rough high bits off with a small grinding wheel in an electric drill (outdoors mounted on a Workmate) and for general smoothing I tried out my two sets of Dremmel style grinding/polishing kits, just to see how they performed. One was low power and kept stopping under load and the other had decent power but a very poor button arrangement to stop the chuck turning whilst tightening on a tool, result….the tool kept working out. It did however prove to me that this approach was what I needed and so I have splashed out on a Dremmel 4000 kit which, so far, is excellent.
I considered leaving the castings in the rough for authenticity and realised that a totally smooth finish may look a bit out of place so I have gone somewhere in between, the resulting painted look is, in my opinion about right.
Thanks again for all the advice. Now I’m battling with turning the darn’d flywheels!!
John