Thanks again to all for the suggestions. I ended up using a variation on the "bumper" suggestion. I found that rubber band abraded to quickly, so a couple of strategic pieces of duct tape and no more abrasion on the aluminum, so while still tedious, it's much better and goes reasonably quickly.
Now for a trivia question----I'm removing the top layer on upright posts (think 4x4 or 2x4). I had a choice of 3 sanders to do the trick.
a) 3x18 belt sander
b) 5"ROS
c) HF Multi tool with sanding pad.
All used 60 grit. Much to my surprise, the HF multi tool removed the material in about 1/2 the time of the other sanders. As a follow up, I hit it with the ROS to remove any sanding marks. I was pretty surprised at the results and how quickly it went. Also, fwiw, I ran the sander for about 2 hrs straight and no thermal issues (hands needed a break though)
Now for a trivia question----I'm removing the top layer on upright posts (think 4x4 or 2x4). I had a choice of 3 sanders to do the trick.
a) 3x18 belt sander
b) 5"ROS
c) HF Multi tool with sanding pad.
All used 60 grit. Much to my surprise, the HF multi tool removed the material in about 1/2 the time of the other sanders. As a follow up, I hit it with the ROS to remove any sanding marks. I was pretty surprised at the results and how quickly it went. Also, fwiw, I ran the sander for about 2 hrs straight and no thermal issues (hands needed a break though)
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