Hugh, I too have just finished the Worden. What I did to give a good finish to the plate was to use a sanding machine, the type that has an oscillating pad. The machine has an oblong base and the sanding sheets are attached with clips at each end.
It gives a very fine scroll finsh on the plate and takes off the rough bumps.
I have not filled the numbers on mine as they seem legible enough anyway. If you want the numbers to stand out then fill them and let it dry for some time before you sand off the plate.
Take care when you make the plate that the collar and screw are fitted. You have to turn a circular 15 deg. end to it. Marking the zero position and the two marks iether side, make sure they are accurate as you cannot see the zero position when the micro collar and knob are fitted and you have to rely on the other two marks to set the plate.
Do not paint the base or side plates as the paint will cause sticking and it will be hard to move.
I made all my bars the same length and had no trouble with that part.
Clive