Introduction: Sanding Saw

Picture of Sanding Saw

For those of us who collect homemade sanding blocks or need to sand around corners and curves, may I present to you this homemade bow sander.

This bow sander is great for tight, curved places and works from both top and bottom.

Maybe your great grandchildren will look at yours someday and ask, “What was that thing for anyway?

If you like the video please Subscribe to my Youtube Channel

I would also apologise for my English as a non-native English speaker some terms are very difficult for me. Forward, Instructable!!

Step 1: Materials and Tools



    Step 2: Handle Saw Part 1 (A & B Pieces)

    Picture of Handle Saw Part 1 (A & B Pieces)

    Draw the contour of the handle saw on a piece of wood. I used Sycamore wood but you an use other type.

    I cut the straight zones with a Japanese Saw and the curved zones with a chisel, a file cut and and finally with a scraper.

    Step 3: Top of the Saw (wooden Rod)

    Picture of Top of the Saw (wooden Rod)

    Since in this project I did not want to use glue, I though to join the pieces A and B with threads. For this I used a woodthreading in both sides of a wooden rod of beech wood (25x380mm or 1"x15")

    Mark the centre of the pieces (A and B) and drill it with a flat wood bit of 22mm in the A piece and 23mm in the B piece.

    Step 4: Wood Tapping

    Picture of Wood Tapping

    Cut the wooden rod at a length of 15" or 380mm and before making the threads we cover it in linseed oil and wrap overnight with film in order to absorb the oil and make easier the threads. Apply also the linseed oil in the hole of the piece A.

    Then we make the threads with the Woodthreading:

    - 1 in piece A as per photograph.

    - 2 in both sides of the wooden rod.

    Step 5: Handle Saw Part 2

    Picture of Handle Saw Part 2

    For a smoother touch of our handle saw round the vertices. I use a spokeshave, a block plane, a gouge cut 3 straight and finally with a grid 280 sandpaper.

    For the inner part I use a Rasping Riffler File .

    Step 6: Wooden Nuts

    Picture of Wooden Nuts

    For the nuts I used oak wood.

    Use a compas to draw the nuts on the wood making a circle and marking a hexagon with it. Drill the centre with a bit of 22mm and make the thread. Then cut the sides of the hexagon with a saw.

    Since we need 2 nuts, we divide the piece into 2 equal nuts with the help of a gauge and a saw.

    Step 7: Assembly of the Sanding Belt

    Picture of Assembly of the Sanding Belt

    Once all the pieces created, we have to locate the sanding belt.

    I leave a drawing with the place where I made the holes but if you have changed the sizes you will have to adapt to yours.

    Step 8: Leather Belt

    Picture of Leather Belt

    So that the paper sanding does not break

    For avoid breaks in the paper sanding while sanding, I created a leather belt. I sewed 2 little rods at both ends but if you prefer you can use contact glue or similar.

    Step 9: Wooden Finish and Final Assembly

    Picture of Wooden Finish and Final Assembly

    Finally, I apply linseed oil to all pieces and assemble what I have called "SAW SANDIG"


    jessyratfink (author)2017-10-04

    Love this!! Looks so much nicer to hold than the flat sanders I've been using. :)

    Yes, I think that is very comfortable , thanks!!

    boffincentral (author)2017-10-01

    Nice execution. I really like it.

    If you can source it locally, Cloth backed sandpaper is available in rolls and widths that would mean you would not need the the leather strip. I think cloth backed sandpaper would be easier to tension too. Less moving parts.

    Using cloth backed sandpaper you could also simplify the way the paper is held. A simple handsaw cut at an angle would probably be enough.

    Yes, you're right, I've also proved it with cloth backed sandpaper and it's not necessary to use the leather strip. Good observation!!!

    gravityisweak (author)2017-09-28

    This is a brilliant piece of work! Both clever, and beautifully designed. You got a great result, well done!

    Thanks for your support, I'm glad to hear that!!

    HjoacoM (author)2017-10-01


    MillennialDIYer (author)2017-09-30

    Don't you think you should disclaim that you're using Amazon Affiliate links? Just for the sake of honesty. I really wish more people here included a disclaimer, which you are supposed to do...

    PeterP93 (author)2017-09-27

    wow, what a great job! Congratulations

    Mikhandmaker. (author)PeterP932017-09-27

    Thanks Peter! :)

    cavalier19 (author)2017-09-26

    superb design & top class craftsmanship. Plan to make one soon

    Mikhandmaker. (author)cavalier192017-09-27

    Thanks for the comment!

    apapercraft (author)2017-09-26

    Wow. This is such a clever idea. It's going to make a sanding work much more comfortable!

    That was my intention, glad you like it!!

    bnelson218 (author)2017-09-26

    What an inventive and great idea! I see innovative things like this and wack my head, wishing I'd thought of it. Good job!

    Mikhandmaker. (author)bnelson2182017-09-26

    I'm happy that you like the idea, thank you very much for your words!!

    StephanP1 (author)2017-09-26

    Great as always, Congratulation Mikel!

    Mikhandmaker. (author)StephanP12017-09-26

    Thank you Stephan!!

    ЕвгенийА19 (author)2017-09-26

    Отличная работа! Про ремень - отличная идея.

    Благодарю вас!

    CaitD1 (author)2017-09-26

    That was AMAZING! I enjoyed watching your techniques as much as the idea for the final product. Do you have an instructable for sharpening your chisels? I can never get mine to cut like butter like yours did.

    Mikhandmaker. (author)CaitD12017-09-26

    I don't have an instructable with that, but you have given me an idea of showing my technique for sharpening chisels. Thank you very much!!!

    Tomas223 (author)2017-09-26

    Your "craftsmanship" and love of Wood shows through your photos. Attention to Detail shows also. Well Done Instructable !!!

    Mikhandmaker. (author)Tomas2232017-09-26

    I love the wood and enjoy a lot working with it, thanks for your support!!

    deluges (author)2017-09-25

    "Maybe your great grandchildren will look at yours someday and ask, “What was that thing for anyway?"

    Story of every tool I made, ever.

    ClenseYourPallet (author)2017-09-24

    Very nice! All of the details makes your really stand out

    Thanks for the comment :)

    rayp1511 (author)2017-09-24

    I haven't seen one before either. I like it. Thanks for posting this.

    Mikhandmaker. (author)rayp15112017-09-25


    DIY Hacks and How Tos (author)2017-09-24

    That is really clever. I have never seen one of these before.

    Thanks Jason!

    About This Instructable




    More by Mikhandmaker.:Drill Press Vise, HomemadeWooden SpokeshaveSanding Saw
    Add instructable to: