Introduction: THE ULTIMATE SANDING BLOCK

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About: Are you interested in DIY Projects? Do you want to make something for your Workshop, your Children or something around the House? Then watch my Videos and do it for yourself or gain a Inspiration out of it.

Introduction :

I always wanted to make a sanding block where I don’t have to hold the sand paper in place, and where the grit change goes really quick.

I found a sanding block in a online store which can do exactly what I want. So I decided to make one my own. I don’t know if my mechanics are the same but I made it as simple as possible.

My YouTube Channel : https://www.youtube.com/channel/UC0HAg66Em50PZyVGQ0LTDOg

Supplies

What you will need :

  • 1/2" (12mm) Plywood
  • 3/4" (21mm) Plywood
  • 3/8“ Axle (A tube, a rod or even a wooden dowel will maybe work)
  • Wood glue
  • Screws
  • Sanding belts

The tools that I used :

  • Table saw
  • Band saw
  • Miter saw
  • Power drill
  • Drill press
  • Disc sander

You can also use other tools to do some of the steps like a jig saw or even a hand saw.

Step 1: Cutting the Lever

Next I have drawn the shape of the lever to 21mm plywood, drilled the hole and cuted it also out at the band saw.

After that I have sand it to the final shape.

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Step 2: Cutting the Three Layers

I first have cut out the parts of the three layers from 1/2"(12mm) and 3/4"(21mm) plywood. The top and bottom layer are identical except the hole for the axle.

The center layer is almost identical to the two other layers. Just the dimensions are different.

You can cut out the shapes with the tools you prefer. I cut it with the table saw. But a band saw or even a jig saw will work also. Cutting by hand should also work if you have the skills.

Important is, that each small part easily can slide in the associated bigger part.

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Step 3: Cutting the Center Layer to Final Shape

Then I have drawn the final shape of the center layer to the plywood and have cut it out at the band saw.

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Step 4: Making the Axle

Then I have cut the axle to length. I used a steel tubing. A solid steel rod or a wooden dowel from hardwood should work too. Use what you have on hand.

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Step 5: Assemble the Basic Sanding Block

The next step was, to glue up the parts. I used glue and nails for all the pieces, except the top layer. To have the top layer removable, i just screwed it on, just in case I have to make some adjustments.

Before I screwed it finally together, I set in the axle and the lever.

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Step 6: Bringing the Sanding Block Into the Final Shape

The last step was to cut and sand it to the final shape. I have cut the angle on the front on the miter saw. then I have sand the bigger radius at the back of the sanding block in small steps. I just have grind a small amount of material in each step, and tried the sanding block with a sanding belt after every step until I had the radius as big as the locking mechanism works perfect.

And then I made the final assembly.

Attachments

Step 7: Video of the Making :

Step 8: Instructional Document (Plans)

UPDATE :

Due to the corona crisis, I lost my job. I get financial support from the state until I find a new job but for a maximum of 1 year. Since this financial support is a lot less than I got before, I am dependent on earning a bit of money on the side. So I decided to sell the plans for the sanding block from now on.

If you want to support me with the purchase of the plans, you can order it here :

www.isimplybuiltit.com

Thank you very much.

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