sanding... lots of sanding... first you prep the wood from the 'dressed' state receive it in from the wood place.... then after all the routing is done ... and then the hand sanding with the 320 and 400... the old chestnut about working thru the numbers applys to sanding... it is sooo much easier to buy all the grades of sandpaper/sanding discs and just work up in steps rather than trying to go straight to the fine one and do lots of sanding with it...

BTW... 5in disc sanders with variable control - ace!!

did I mention lots of sanding?!

... unfortunately power tools only go so far and a few hours of my life have been spent snuggled up with a sanding block and 400grit sandpaper...