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Personally, I would never use an emery wheel/stone on a dremel for task like this. i am also not sold on the sanding sleeves, but I frequently use softer stuff like the little buffing wheels and...

Depends how you define "hand sanding" Remember that all of the post forge shaping of nihonto is done by "hand sanding." and scraping. So, if you have a month to squat in front of a set of...