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We're drinking from the same tap my brother. I'm taking the paint off in layers. Pure water, needle scaler (not the best tool for speed or thin metal) and my grinder with $5 HF polycarbide discs.
I have considered liquid stripper, but questioned the cost per sq foot.
http://youtu.be/ETVSlQHbzrs
I can't think of any way to save the sand. You would need an enclosed space, some way to dry it, and then screens to sift it.
For $4/50lbs it just isn't worth the effort in my opinion. (If you buy it by the pallet, and wheedle the department manager, you might be able to get it even cheaper.)
If you want a FAR cheaper alternative for media, try Home Depot Quickcrete Fine Sand. It may only cut at 75% of the speed, but it is 1/3 the cost.
But, do you think that glass might be better for fast cuts in the hard to reach spots...
Okay... how I missed this thread for a week is anyone's guess.
What sand are you using?
+100 on the phosphoric acid. http://www.homedepot.com/p/Klean-Strip-1-gal-Phosphoric-Prep-and-Etch-GKPA30220/100406369
I can't wait for pics and vids!
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