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.

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Step 1: 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.

Step 2: 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.

Step 3: 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.

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.

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.

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.

Step 7: Video of the Making :

Step 8: Instructional Document (Plans) / Free Download

The plans are for free. But if you valuate my work and you think my plans are worth it, you can donate a few bucks to my PAYPAL-Account. You don’t have to but I would really appreciate that. And you would support my YouTube Channel and my work with it. Thank you!

You will find a QR-Code and a link to my PAYPAL-Account in the downloadable Instructions.

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

First Time Author Contest

This is an entry in the
First Time Author Contest

2 People Made This Project!

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10 Discussions

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arbasses

1 day ago

Many thanks for sharing your drawings & instruction !!!

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Karl Gabel

26 days ago

Awesome plans - have needed something like this for a while. My current sanding blocks take too much time to set up.

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karlbamforth

4 weeks ago

Excellent. I have been planning on making something like this but never got my head around how to tension the belt. Thank you for showing us how it is done. You get my vote.

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DanPro

4 weeks ago

Great idea! I would like to have a few of these with different grit papers.
I see its easy enough to change the belts but being able to just grab the next grit and go would be convenient. And hey if they are free why not.
Nice job, and good luck in the contest.

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JanM90

4 weeks ago

Nice one! I have a little tip about sanding belts in the size you've chosen. They can often be found in Lidl stores, because they fit a small belt sander, named Parkside, sold there. I recently bought three packed sets with six different grain sizes for only € 2 each in Lidl - they also fits my own sander, produced by Skill.

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I SIMPLY BUILT ITAnmius2

Answer 4 weeks ago

You should get the sanding belts in every hardware store or on amazon.