Jon wrote:What size sanding disk and grit are you using to remove the paint?
Here is my favourite tool for removing old paint and surface rust. I am not sure that everyone is familiar with it so I thought I would show a pic of it.
From the beginning it was only manufactured by 3M (I think they invented it) and this product is called Scotch-brite. Quite costly at a start but now I use to buy this tool in a discount store called Biltema (only here in Sweden).
I think it works very well myself and I can warmly recommend it. The only disadvantage is that it creates a lot of dust, but except for that it is great product. One positive thing is that it doesn´t grind off anything from the sheet metal.
The disc is replaceable so you do not need to replace the shaft every time you switch discs. I prefer large diameter discs because the job gets done quicker with them.