CUSTOM

Sanding Block

© 2017 Cruz Bay Publishing, Inc.

custom
Sanding
Block
Some scrap wood and a
few simple steps are all it
takes to build this basic,
must-have shop tool.
One of the most basic It’s made from
1 FIGURE
tools every shop needs is a pine so it’s light-
simple sanding block. I’ve used weight. This means less
everything from a piece of scrap fatigue during long periods of
wood to a specially manufac- sanding. And finally, the block
tured block to get the job done. lets you use either standard or
But none of them ever really had self-adhesive sandpaper.
the features I needed, so I built Shaping the Block. Building the
the custom sanding block you sanding block is a snap. All you’ll
see in the photo above. need are two pieces of pine — one
This sanding block provides 1/ "-thick piece for the base and a
2
a good secure grip and still fits second 2"-thick piece to form the
comfortably in my hand. Plus, the handle. Then you’ll need to clamp
size and shape provide good vis- the blocks together and trace the
ibility of the surface being sanded pattern shown below on to them.
and allow me to get into even the I made a trip to the band saw to
tightest corners with ease. cut the inside curve for the handle.

Pattern

1 WoodsmithPlans.com SN08722 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.
 a. a.
2 3

b.

Then it was a simple matter to For the clamping pad, I used a Cork Base. I added a cork base
glue the two pieces together, like piece of 1/4" hardboard that I cut to the bottom of my block. The
you see in Figure 1. Now you can slightly narrower (1/32") than the cork provides a nice base and
use the band saw again to cut the dado. To provide some “grip” helps keep the sandpaper from
outside shape of the top of the block. so the sandpaper wouldn’t slip slipping around as you sand. You
Finally, sand the top and bottom to around during use, I added a can use other materials, such as
provide a smooth look and feel. small piece of sandpaper along the felt or rubber, for this as well.
Clamping Pad Dado. To keep lower edge of the clamping pad. I used a spray adhesive to attach
the sandpaper tightly stretched Back Sandpaper Slot. You’ll the cork. This way, I didn’t have to
over the block, you’ll need to also need to hold the sandpaper worry about any glue squeezing
secure the sandpaper in place at in place at the back of the block. through the porous cork when I
the front. For this, all you need This is done by simply cutting attached it to the sanding block.
to do is cut a shallow dado to a small slot at the back of the Using the Block. Now, all
hold the clamping pad across block as shown in Figure 4a. that’s left is to install the sand-
the front of the block. I did this You’ll find a thin-kerf hand saw paper. Since the block accepts a
by making two shallow cuts at works great for this. Just make a quarter sheet of sandpaper, this
the band saw to define the edges cut at 45°and then pass a piece is easy. Just trim the sheet, slip
and then cleaning out the waste of sandpaper through the slot a one end in the back groove, and
with a sharp chisel. few of times until the sandpaper secure the other end under the
Bevel the Sides. Since one of the slides easily in place. front clamping pad.
goals of this project was to be able
to sand into a corner without my
fingers getting in the way, I beveled
the sides of the block. This was easy.
4 EXPLODED VIEW
a.
I just used a small piece of scrap to
raise one edge of the sanding block
to the desired bevel angle, like you
see in Figure 2, and then cut both
sides with a couple of quick passes
of the band saw. Once this is done
you’re ready to make a clamping
pad to hold the sandpaper in place
at the front of the block.
Clamping Pad. Since you’ve
already cut the dado, all you
need to do is install a threaded
insert to hold a clamping pad
and knob in place. I used my drill
press to first drill a hole at 90° to
the dado as shown in Figures 3
and 3a. Then install the threaded
insert (Figure 3b).

2 WoodsmithPlans.com SN08722 ©2017 Cruz Bay Publishing, Inc. All Rights Reserved.