Removing all anodizing is a bad idea, IMO. Lightly blast with 120 AO. Yes, some anodizing needs more blasting than others but it does not need to be completely removed.
So how are you spraying .001 inside the URX4 rail you have posted?
I've listened to a good bit of the manufacturers(NIC/Cerakote) advice only to find they are wrong at times.
I agree with your advice comment - I use 80 grit AO for example rather than 100-120 grit. Generally speaking, however, I do feel it's advantageous to take into account insight provided by those who've created a product.
I should have used a different word than "completely" above the URX pic. It was probably closer to 85%-90% removed. Even then, what specifically makes you feel that removing anodizing is a bad idea? Aluminum is already oxidized when it makes contact with the air. It's not going to rust and you're just replacing a raised surface with one of a different color. That's really it. Let's say you're doing a multi-color camo or Kryptek job and youre overlapping colors. It's pretty difficult to keep applied paint layers to a uniform .001" when put in that context. If you're putting more paint on you'll more than likely need more margin of error to ensure it turns out like you want it (this & time spent blasting is why I use 80 grit).
With Cerakote, the goal should be uniformity around cut depth and shade - not how much anodizing is left. You want to end up with coated parts that are as close to the exact size they were before hand. If that means your anodizing comes off, then it was a weak HA job anyway and you're no worse off. If you're coating over an HA'd part with the only prep being degreasing then your finished product will have a surface that's raised more than it should be leading to multiple sizing/fit issues. One might think its awesome until you get your hands on one that was prepped appropriately. Cerakote on top of HA is not the "best of both worlds" it's just two of the same on top of each other.
Cerakote essentially does the same thing HA does, it's simply applied differently, adheres differently and can vary in color and uniformity. They both increase surface hardness, protect against abrasion & corrosion, increase impact resistance, etc. The only real difference is the way they bond to the aluminum and the flexibility of each. That's about it with aluminum. Steel is a completely different story.
Sawman, to answer your question, the .001" aspect isn't as relevant when it's the inside of the handguard considering the minute variation in size wouldn't affect anything in that particular spot. Uniformity was the goal. I cut down the handguard and milled holes through the cross slots to reduce weight. Instead of just touching up the edges around those areas I refinished the entire handguard to ensure it had the same color and durability throughout. Used the same HVLP as I did on everything else...