Step 3: attach sanding disk to the other side

attach sanding disk (sand paper out) to the other side of the foam.  

now you have a thickened piece of sand paper backed by foam that can follow concave and convex surfaces
<p>Great idea but this doesn't look like polystyrene - no little balls. Is it a different type of polystyrene to the usual packaging material? Can you remember where you got it?</p>
Excellent, though I never have patience for orbital sanders. Used to using angle grinders with flap disk wheels on metal, so invariably my laziness leads to using this on wood as well, of course my wood surfaces end up feeling smooth, but undulated like crazy! Your is a much better idea! And I promise not to try this mod with my angle grinder attachment, (though I did ponder it for a sec')
hell of a idea (danny tech shop SF these can save a lot of ware on my fingers

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