I need to paint my M1009. Mine is camo but I was thinking of the sand color. How much prep was involved? Did you have to sand it all or just in spots? What did you use to mask the windows and lights? Did you have to remove the grill cover? Looking at your M1009 has inspired me!!
I powerwashed it at the quarter wash for 30 minutes, going ever every nook and cranny. I brought it home, sanded out places where there chips in the paint and feathered them out. I didn't do any bodywork. I plan on using it offroad primarily, so I wasn't concerned about little dents and what not. I went over the rest of the truck with a brillo pad type thing in an angle grinder. CARC is pretty rough as is, I just wanted to scuff it up some more. I didn't actually strip much paint off. Then I went back to the car wash and powerwashed it again.
Brought it home and taped off. I used just regular masking tape and taped around all the window rubber and stuff. Once I had the rubber taped off, I used newspaper to cover the glass and sealed it to the tape around the rubber. That took longer than the sanding! I did take off the grill and headlight doors. I took out the headlights, tailights, markers, etc. Wiped the whole thing down with paint thinner and a lintless cloth. Followed up with a tack cloth.
Then I just started painting. Its certainly not a show quality job, but for what it is, a .mil vehicle, I would say its pretty "correct". I did it all in my driveway..