No sanding actually makes it rougher, it doesn't react well to abrasion. I thought of using maybe an iron and wax paper to smooth it out. Another option would be to make a mold and pour the stuff into it but that's another project for someone else, preferably someone with a milling machine in their garage. I'm happy with my lumpy, lop sided ugly bracket covered with my fingerprints and theres a dog hair in there somewhere too....it's a ratty old bike that has it where it counts (motor, electrics, soon the suspension and brakes) but not so much cosmeticly.