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I varnished my toe rail on my Endev this summer. 42' boat and the toe rail is about 6" wide. It already had 2 coats from the PO so this is over coating.
I think you are sanding way too much. A 1/3 piece of 220 paper lasted about half the job. You only need to barely scuff the surface and if you put the coat on soon enough after the previous coat you don't need to sand at all. I used Flagship and their product specialist said a scotchbrite pad would be fine unless it has sat for a week.
I use foam brushes and go slow.
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