Hand sanding is fine. I only hand sand filler and then use the DA with high grit to take out small sanding scratches.
Hand sanding with a block will keep everything straight.
Painting aluminum?
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Re: Painting aluminum?
"There he goes. One of God's own prototypes. A high-powered mutant of some kind never even considered for mass production. Too weird to live, and too rare to die." - Fear and Loathing