it'll take a looong time using a wire brush , as long as you don't keep the brush on bare metal for long, it won't hurt anything, I'm using a Porter Cable on high speed with 36 grit to remove 40 year old bondo and paint off 69 Dart right now,it's piece of cake
__________________
Stefan B. Do what's right,not what's easy!
3M makes some great wheels that remove paint,bondo,etc. The problem with using a grinder is you will gouge the metal. It's much safer to use a dual action sander, which is less likely to hurt the metal.
start with a chemical stripper.... id use a DA next, the pads are cheap and it works fast, and strat with a 36 or 40 grid and work your way up... and when you are done with one panel... spray it with epoxy primer, then move on.. (and spend some time keeping the shop clean (or atlieast clean'ish) it will look like a warzone in no time if you dont)
__________________
Elwood:We're 105 miles from Chicago, we have a full tank of gas, half pack of cigarettes, it's dark out and we're wearing sunglasses.
Jake: Hit it.
If you use chemical stripper make sure you clean up the metal really good before priming it could cause adhesion problems down the road. I use laquer thiner and a red scotchbrite and then I use a d.a. and then clean it again. I also use metal wire brushes alot, like everyone else said dont stay in one spot to long or you'll warp the metal.
If you want all the material off quick, the buy a 3m clean and strip, or something similar, put it on your electric hand grinder and go to town... ...Fast!!! won't remove or gouge metal... the best way yet ....imoa
i'm not a professional by any means, but i haven't found a chemical stripper that you can buy at a stroe that works worth a ****. I've let it sit on there up to and hour or more, and it really doesn't do anything. I may be expecting it to do more, but I use the 3m paint stripper pad on my grinder, and it works awesome. takes a while longer, but it doesn't put as much heat on it at all. just my .02
If it is layed on thick you can use a scraper warmed up with a heat gun it will peal right off in large sections. Then use chemical to strip the rest. Using 36 on a panel puts in a lot of heat and a lot of sanding scratches that can show up later. 36 can go through a panel or take the line or edge right off it.
When using stripper try and lay a piece of plastic over it. It makes it more effective.