Introduction: Radius Sanding Scroll Saw Mod

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About: I am a metal fabricator at DA Moore in Concord, NC. I also machine, weld, and draw CAD/CAM parts on a daily basis. In my spare time at work I like to make things that pop into my head. I have to keep the pr…

I recently needed a way to sand a radius on some curved lettering with my scroll saw. For this, my first Instructable, you'll likely need:

  • Scroll Saw (usually helps)
  • Scroll Saw Blade (pinned), I had a damaged cheapo blade
  • Wooden Dowel Rod, in this case I used a 5A drumstick
  • 3/16" drill bit, drill
  • Wood Glue
  • Electrical Tape
  • 3M Spray Adhesive (love this stuff)
  • Sandpaper of your choosing

Step 1: Assembly

I sawed off a chunk about 2-1/2" to 3" and drilled through both ends with a pilot drill and finished with the 3/16". Once I fit the blade through the hole I wrapped the Electrical tape around one end as to plug the other end and keep the rod in place. I did end up taking a thin piece of shim to center the blade at the open end. I proceeded to fill the hole with drops of wood glue until it was reasonably full. I then stood it upright to cure (inside this random spool of solder wire).

Step 2: Applying the Sandpaper

Here I coated the back of the paper with the spray adhesive and rolled the blade onto it.

Step 3: The Resting Surface

I cut a large hole to accommodate the cylinder and away I went! Don't mind my unusual clamping method. I don't own a pair of vice clamps (yet) so I have been using a cheapo pair of micrometers to bite down and it works darn well.

Best part is that you can reuse the rod and keep applying paper, and you can even flip it upside down for anther surface to use!

Thanks for checking this out, and I should return soon for another instructable!