I use mine mainly to level 5 piece doors, and 3-5 passes with 100 grit start is more the norm. Think more like 1/32 with 150 grit, or even less. I have a 25" General and it doesn't use Velcro, but 3/32 in a single pass is way too much. Any tips? I guess it's back to the RO till I feel like ruining the last piece of Velcro I have. I would expect it to be able to work harder than how I'm using it, but the Velcro paper system just keeps failing. I don't think I'm taking too much off - light passes with 150, no more than 3/32, and medium to slow speed. It's getting expensive to learn this way, and I'm tired of ordering extra stuff. Once I finally get it on good, it ends up tearing and throwing the paper within a few boards, ruining the Velcro with it. I fight it, putting it on over and over, trying to get it flat. I'm having trouble after trouble with the sanding paper not being flat on the drum. I have a Woodmaster planer/molder and supposed drum sander too.
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