CB wrote:
Sounds like a lot of effort for a few ounces savings, and think of the
the potential damage if the power tool slips... A few swipes with
medium sandpaper to take the sharp edge off seems good enough for me.
Maybe round off the corners a bit (1/16" radius) in the cockpit near
the knees and elbows, but that's about all I'd do.

Sounds like a job for a block plane, chamfering plane, spokeshave,
or card scraper any of which will be neater and faster than sandpaper.

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FF