Sandpaper sheet cutter

Picture of Sandpaper sheet cutter

I made it at TechShop http://www.techshop.ws

If you have a 1/3 sheet or 1/4 sheet finish sander, then you know that pre-cut sheets of sandpaper can be purchased, but how many times have you cut your own from a full sheet? You probably cut it crooked with a utility knife, dulled your scissors, or tore the sheet.

Well not any more. Now you can easily cut perfectly straight 1/4, 1/3 or 1/2 sheets every time.

Materials needed:

Scrap 3/4" plywood, particle board or MDF
(1) 10" hacksaw blade (longer blades can be used, but you will need to adjust the design to fit.)
(2) #6 x 3/4" round head wood screws

Tools needed:

Laser engraver/cutter (available at TechShop)

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Step 1: Layout

Picture of Layout

Sketch a layout, such as the one shown in this step, to mark the proper sizes for the different size sheets, relative to the cutting edge of the saw blade.

To save yourself a step, you can also download our .DXF and CorelDRAW files at http://www.lime3D.net/instructables/sandpaper_cutter.zip

Step 2:

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Using the 60 watt Epilog laser at TechShop, etch the lines and text using the vector cutting settings.

Tip: Vector cutting material with settings that do not cut all the way through your material will result in razor sharp text and images.

Step 3: Finish woodwork

Picture of Finish woodwork

Using the outline created with the laser, cut out the board with the band saw (as shown in the photo) or the table saw.

Sand the edges and round off the corners with a sander, the flat areas (to remove any soot marks) with a finish sander, and drill pilot holes for the screws as shown.

Step 4: Attach the blade

Picture of Attach the blade

Fasten the hacksaw blade to the board with two #6 wood screws. To allow the sandpaper to slide under the blade, do not tighten the screws all the way down.

Step 5: Cut your sandpaper

Picture of Cut your sandpaper

Slide a piece of sandpaper under the blade, and align the edge to the appropriate mark.

To cut the sheet, simply pull it up against the blade, and it will cut perfect sheets every time.

About lime3D:

I have been designing products in the automotive, aerospace, medical, defense and consumer products industries for over 30 years. I am an "Inventor for Hire", so if there is something you need designed or built, just send me a message, or stop by http://www.lime3D.net , and maybe we can do business!

anasdad2 years ago
Not exactly rocket scientist, but an outstanding job! I will be making one for my shop. thanks for posting it!
FN643 years ago
I've dulled my share of utility blades.. I LIKE IT!!!!
Gonna have me one of these by tomorrow afternoon.
Pretty smart idea!!
lime3D (author)  coolbeansbaby683 years ago
Thanks. You could also skip most of the construction steps, and just screw a hacksaw blade to your workbench, and draw a few guidelines. But at least this version is portable.
Denger3 years ago
Simple yet effective! Nice 'structable.