Introduction: How to Make a Bow Sander

Picture of How to Make a Bow Sander

A bow Sander is a fantastic tool for sanding handles and other rounded or molded surfaces. This design is set up to use a belt from a belt sander so you can quickly switch in and out the different belts and keep going. It is faster and easier to use than a sanding sponge and far cheaper as you can get 3-4 belts out of one standing belt.

Tools Needed:

#4 Hand plane setup for smoothing:

Panel saw:

Round bottom spokeshave:

File set:

Plow Plane:

Supplies needed:

Boiled Linseed Oil:

Past Wax:

Belt Sander Belts:

Wood scraps: The ones laying on the shop floor

Step 1: Start Shapeing the End Caps

Picture of Start Shapeing the End Caps

the end caps only need to be out of blocks 1.5" x 3/4" X 1" but working with blocks that small can be difficult. So I like to shape a larger block and then cut the small blocks off of that. I start by cutting a 3/16" wide groove along the center of one edge of a 3/4" wide piece of scrap. The groove should be about 3/8-1/2" deep This can be pine, hardwood, or whatever is in the shop. then I round the corner on either side of that block with a small plane, rasp or Spokeshave. this ends up being about 1/4" round over

Step 2: Cut Out the End Caps

Picture of Cut Out the End Caps

Next, I use a panel saw or tenon saw to rip off 1 1/4" wide strip off the piece that I just shaped. This will give you a stick 3/4" X 1 1/4" strip with a groove along one edge. Next, round over the other two edge corners so that all 4 long corners are rounded to about a 1/4" round over. Last cut off 1" long chunks of this stick. you will need 2 blocks for each bow sander you want to make.

Step 3: Cut the Beam

Picture of Cut the Beam

For the beam, I used a scrap of oak but you could use most any wood as long as it has a bit of flex. I used a hand plane to bring it down to 3/16" thick then ripped it down to 1" wide. the total length is 8 1/4"

Step 4: Bend It to Shape

Picture of Bend It to Shape

I put the beam in a pot of boiling water for about 10-15 minutes till it becomes flexible. Next, carefully pull it out with gloves or tongs and slide on the end caps you made earlier and slide the whole thing into a sanding belt. Let it dry overnight and it will hold that shape.

Step 5: FINISH IT!!!

Picture of FINISH IT!!!

I do not glue the parts together as the tension of the belt will keep them in place, but that is up to you. For a finish, I use Boiled linseed oil and Past Wax. I use some scissors to cut down the belts to 1" wide and have a stock for the future. then it is all set to go.


I love this idea, definitly have to make one!

thanks! I use mine all the time!

getysburg (author)2017-02-24

This is a really cool , and useful project thanks for sharing it.

woodbywright (author)getysburg 2017-02-24

thanks! glad you like it. I use it more then I expected.

getysburg (author)woodbywright2017-02-24

I'll bet , it must come in really handy for tight curves. Does it wear on your hand much?

woodbywright (author)getysburg 2017-02-25

very useful for that. and, no there are several ways to hold it so there is no rubbing on your hands.

getysburg (author)woodbywright2017-02-25


Ilovegold (author)2017-02-25

I think I will make one for my friend he wanted something like this

woodbywright (author)Ilovegold2017-02-25

That would make a great quick present!

About This Instructable




Bio: I have been working with wood since I could stumble into the shop with my dad. About a year ago I moved into a house ... More »
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