Hey, I have a question too, I have 3 watchamacallits for a drill that I think would work for rust if the 3m stuff works. 1 has a head on it maybe 2 inches that looks like a mini version of a grinder disc and is about 1 centimeter?(not good on the centimeters length)thick. The others are kind of like the 3m discs but are made with steel(?) wires going down towards what you're working on instead of the other way like a grinder.
Never mind, just clicked on the link for flap discs and found out that what I have that I got from my dad is flap wheels.
Achipmunk, I think I know what your problem was. He was probably doing it with too high of rpms. The flap wheels I have say Max is 4500 rpm. Maybe that would have been helpful. Didn't those say anything about maximum rpm? Mine also say WERE EYE PROTECTION!!!