David uses the Enco model rotary tool that is much like the Foredom.
There is always going to be a tedious amount of hand-sanding. But there are times when things like Cratex wheels can help.
Files.
Sandpaper.
Shim stock with sandpaper wrapped around it.
Hand sanding.
Hand sanding.
The higher rpm tool you have, the more control you will have as there will be very little torque. Dremel type units are inexpensive and will do quite a lot. You can buy a 55,000 rpm air driven rotary unit from Harbor Freight for $35 (it's the exact same one places like MSC sell for $90).
Higher on the list is the Foredom, but you'll be looking at $250-350 depending on model and purchase location. Most of their units are 1/8 hp, but they do have one in 1/4 hp.
The finer detail is much easier to achieve with super high rpm's and one of the highest on that list would be the Paragrave, turning at 400,000 rpm's, but coming in at around $1000. I have a Turbo-Carver which is a lower quality version, but it only cost me $210 last April at the OKCA show. The high rpm units all run off of air (i.e. a dentist drill).
Hand sanding.
Hand sanding.
Hand sanding.
Best of luck
Nick
