Forgot to update this thread, but back in April or May I took the car back and had them remount two tires to try and solve the bead leak.
When they removed the tires, both wheels are essentially flawless on the inside, no corrosion behind the lip or the on the bead sealing surface, none anywhere inside the rim that we could spot.
The installer is as stumped as I am. He wiped the sealing surface with some sort of solvent and put some extra bead sealer like he did on the last one, and both seem fine now. I haven't put soap on it, but I've been watching tire pressure over the last couple months and they seem to be holding air fine. I've never had a tire give me this much difficulty sealing the bead, but I don't know what about the tire would cause it. Maybe just bad luck.
To be honest, I'd rather have the OE refinished. The aftermarkets are of questionable quality imho. I have them for all my winter tires. So not only do I prefer to keep the look OE, but the OE rims are better imho. I see replicas on eBay for only $150--look identical and even have JWL logos which I think are counterfeited. But like you, I don't want to pay $400 for cosmetic. From experience back to 2000....I find that OE are yes, heavier, but they don't get dented from a pothole. My wife has ruined 2 sets of aftermarket rims where the lip simply bent upon striking a pothole...My winter set of alloy wheels have been through 15 winters, and 2 of them have developed a slow leak (2 psi drop per month) during the last 2 years. The wheels have a few spots of bubbling paint, two have curb rash, and all have bead corrosion.
I checked a local wheel repair shop website for the cost of having the bead corrosion removed, the curb rash repaired, and a full repaint, and the cost is a minimum of $400 for 4 wheels. I can get a set of new 17" alloys at tire rack for $600, with free shipping. I think I will be buying a new set of alloys come spring time.
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Yes, any brushing, sanding should be followed by sealing. I prefer clear laquer in a matte finish for alloys. Just a quick spray with the pretty side of the wheel facing down. Steel wheels I like matte or gloss black on the beads. I usually paint the face of my steel wheels with hammerite silver. Easy to touch up. One more thing I will let bead paint/sealer cure for one to three weeks before mounting tires. I run dedicated snow tires so messing with cleaning, painting and curing is left to the off season of the set needing attention.The problem with taking a wire wheel or even brush to bead seat corrosion is it takes any clear coat off the rim and just makes the issue worse in the long run. I always ask tire shops to be gentle cleaning and to apply bead sealer if I don't do it myself, but once the corrosion starts without sanding and reclearing it will just get worse in time...