2nd sander?

Maybe one of these would have helped:

http://www.festool.co.uk/Products/Accessories/Pages/Detail.aspx?pid=496647&name=Sanding-pad-150-mm-IP-STF-D-150-17-MJ

Besides helping the abrasive to better follow the curve - I suppose it's possible
there could be localised over-heating if not careful when sanding without the interface pad.

Richard

(edit:  come to think about it, were you using a soft pad on the sander - the sanders come with the
'medium' one, although many use hard pads for stripping, and, to maintain crisp edges.)
 
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