A very good description of the process.
I used to paint in the afternoon and return in the morning. It was one of the first things I would do when I picked up a new 5090. I used to replace the shields, but kept the flash lamps unless they were obviously shot. The paint makes such a huge difference that the machine will tolerate older flash lamps. In fact, a dingy tub is what burns through flash lamps and melts the flash lamp shields.
Ray's point about moving the tub down (choosing 65%) is a areally good one. It's easy to forget.
The first one is the hardest. There are nooks and crannys and corners that are hard to get the roller and brush into. I used a 2-3 inch roller and several of the throwaway foam brushes.
It IS time-consuming and the customer has to be talked into the labor expense. He will make up the expense pretty quickly through longer lasting flash lamps and reduced toner consumption. We used to get the paint through OEMSUPPLYCo The paint from Xerox would always be old and dried out. Xerox Tech paint a tub??? Dream on!
This discussion seems moot now, with the "almost free" availability of DocuTechs, especially the DT135. Although not really a viable player anymore (unless your workload is simple, non-variable printing like manuals), it would still make a great replacement for the 5090. Good bye handler, good bye optics!