Mantle Option 1

Dremel maybe? I see what you mean as to it not being smoothed out, but it seems so much a waste... Could do the old fashioned bit of making a small roll of sandpaper and just going up and down the grooves that way, tedious I'm sure -- but may work...

Cant wait to see your project finished! I simple adore everything 'English'!

I would suggest a Dremel, too, but if you are concerned about that with the kids (I know you hand sand a lot), you could just get an electric nail file? Something narrow, definitely. What about sandpaper around a small dowel (toothpick)?

You spend so much time on these, it would be a shame for it to become scrap!

Thanks for the suggestions.

I used a dremel to put the grooves in, but obviously it got away from me often. I'm wondering if turning the speed down or way up may allow for better control. I'm dreading the thought of hand sanding out the kinks, but that may be the only way.

Not sure if you've the same model dremel as I have, but I know if I turn mine to the lower levels it seems to catch a bit more I'd say, but on the higher speeds -- well, you just have to really pay attention and not let it get away from you... Rather much one of those darned if you do darned if you don't type situations. Rather thinking the sandpaper around the dowel may be the best at this point.