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Re: Sanding..a must?
Well in regards to polishing sanding is not always necessary. Many people including myself will not sand clearcoats. You could just use a rubbing compound until you have gotten rid of orange peel. This is actually a form of sanding but there is alot less risk of burning through the clearcoat instead of sanding, then compounding it. Its really a judgment call if you think the clear is too thin then compound and wax it smooth. To be safe I usually apply alot of clear coats especially to metallic colors. Depending on the orange peel I will compound it or use micromesh polishing pads and then wax it.
There is virtually no way to get out of sanding in the whole painting process. You have to sand mold lines and you have to get the body smooth. If you mean minimal sanding in color and clear coats then you need to take especially good care of the build in primer stage. Get the primer smooth, sand it with fine grit, even tooth paste works, wash it and make sure its dust free.
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