seems like a lot of sparks for sand paper ??

http://www.youtube.com/watch?v=UXXM6i3FJ5s

also - how is a flapper disc for removing layers of paint and bondo???

Its the least aggressive abrasive you can use.
So, while it will create a lot of heat based upon how long you need to use it in one spot, it will remove the least amount of metal...

I would use a more aggressive setup for paint removal, and with your lack of compressed air, I would suggest you look for drill and grinder based sandpaper systems....

another simple tool is a random orbital electric sander....

rich

I noticed that the porosity isn't there anymore. Good! You either got your gas dialed in or your cleaning your material better. You live in a damp area and moisture can cause that also. Keep on keeping on.

Nice work Jim! Have to do that to my car soon. Let me know when you'll be in the area