Thanks, everyone (especially Charlie for the detailed shopping list!)
I ended up ordering the cheap bag (actually, two, because of the order-size minimum) of 1” wheels from Surplus Sales of Nebraska. They’re definitely softer than the harder ones I’ve bought from Cleaveland; they take off very little material, so you’ll run them against edges for longer than the harder ones, and it’s really hard to keep from wearing them unevenly since you’re running them longer to accomplish the same smoothing. Holding them at an angle helps; I think I got most of my wear when deburring inside edges of lightening holes, where it’s harder to maintain the angle in a circular or oblong opening.
I also bought the Harbor Freight “Roloc-like” kit - using the blue “fine” disk, it’s been great for edge deburring. The maroon “medium” disk worked ok too, but I prefer the “fine” - it took material off more quickly than the cheap 1” wheel, without much wear: I did one pass perpendicular to the edge, then took off the small burrs it left with a quick pass with a hand pad. It also worked pretty good deburring the crannies between flanges. The 3” pad on the 2” holder also worked good, with more clearance for crannies. (Tried using it to scuff a rib surface - that didn’t go so well, so I’ll stick to the maroon or gray hand pads)
Thanks again, all, for the good advice!
