Totally agree with your method—especially the skim coat trick. Learned that one the hard way after sanding aggressively and turning my basement into a dust storm... wife wasn't thrilled. Another thing I've found helpful is using a damp sponge for the final smoothing pass instead of sandpaper. It takes a bit of practice, but once you get the hang of it, there's even less dust and cleanup involved. Plus, fewer dirty looks from family members is always a bonus.
"Another thing I've found helpful is using a damp sponge for the final smoothing pass instead of sandpaper."
I've tried the damp sponge method myself and agree it's a lifesaver for cutting down dust. One thing I'd add—make sure you're using a firm sponge, not one of those squishy kitchen types, as it gives you way better control over the surface. Curious though, have you (or anyone else) experimented with drywall sanding screens? They're supposed to reduce clogging, but wondering if they really cut down on dust or if it's mostly marketing hype...
I've had pretty good luck with sanding screens, actually. They definitely don't clog as quickly as regular sandpaper, which is nice because you don't have to stop every five minutes to bang it clean. As for dust...well, there's still plenty of it, unfortunately. Maybe slightly less than regular paper, but not a huge difference in my experience. I usually pair them with one of those sanding poles hooked up to my shop vac—makes a noticeable dent in the mess.
Funny story though, first time I tried the damp sponge method was in my 1920s fixer-upper. Thought I'd discovered drywall magic until daylight hit the walls the next morning, and I saw every little ripple and bump I'd missed. Lesson learned: natural daylight is brutally honest. Now I always check my joints during the day before calling it good.
Have you tried shining a bright LED work light at an angle across the joints while sanding? It highlights every tiny imperfection—sometimes depressingly so, lol—but it saves you from that nasty daylight surprise the next morning. Also, curious...what grit screens are you using?
"Have you tried shining a bright LED work light at an angle across the joints while sanding?"
Tried that once, honestly drove me nuts chasing every tiny shadow. Found natural daylight through a window way less frustrating. Usually stick to 150 grit screens, anything finer feels like overkill.
