Description
You can make a sanding block using thumbtacks and a piece of 2x4. As long as you have plenty of tacks and don’t mind bending a few, they hold the paper down pretty well.
But I’m no more a fan of these than rubber sanding blocks. Getting the paper tight can be difficult, so it shifts or tears while sanding, and replacing it isn't much fun either. The tacks can be hard to pull out, so I use an ugly chisel to pop them loose…hoping I don’t break the heads off.
And did I say paper? Paper wears out fast and tears easily.
Then I got the idea of using sanding belts. These spinning monsters use cloth-backed abrasives, and come on…they last longer than any sandpaper I’ve ever used. The cloth backing resists tearing, while layers of bonding resin hold the abrasive media in place against the heat and forces of powered sanding.
So what if we could use a sanding belt as a sanding block?
I found some 18” sanding belts that are perfect for these.
We'll use a 2x4 that's eight and a half inches long and an inch and a quarter wide. Measure in an inch and a quarter, then six and 5/16 inches. Add a 3/4” dowel on one end and an inch and a quarter dowel on the other, tracing around both.
Now draw a line connecting the tops of the dowel marks and rip it on the bandsaw, keeping the cut clean and flat. Next, cut a notch at each end, staying inside the perimeters we drew.
No glue is needed. Just taper one dowel so it slides in easily but tightens when tapped into place. And these things are super tight…so tight you'll need a mallet and another dowel to knock them out.
We want the belt tight and the sanding surface flat, because uneven support beneath the abrasive can leave an uneven surface on our projects.
But the best part is the versatility. You can hand sand with it or chuck it up in a vise. The rounded ends let you sand inside curves, while the flat surface helps maintain flat edges and faces.
The thumbtack does have one advantage, though. You can use it to attach it to sandpaper to custom rounded or odd-shaped blocks. Sometimes the best sanding block is one that matches the shape you're sanding.
LINK IN THE DESCRIPTION
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