Ergonomic Sanding Block

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Project by DYNO360 posted 07-30-2010 02:36 AM 2563 views 12 times favorited 7 comments Add to Favorites Watch

I got tired of just wraping sandpaper around a block of wood. Sometimes I would sand away part of my little finger. Ouch! And it just didn’t fit my hand right. So I designed a quarter sheet sanding block. A machine screw provides the clamping force to hold the two pieces together. The bottom section starts with a good piece of plywood with a lot of plys for dimensional stability. I counterbored the plywood and then drilled a through hole. After installing the threaded insert, I glued on a piece of hardwood for the face that would backup the sandpaper. I also installed two dowels of different sizes to register the top to the bottom. The top is just a piece of 2×4 drilled to accept the dowels and the machine screw. I experimented with a wood rasp to make the top fit the palm of my hand. I also made a “Jumbo” model by laminating another piece of wood onto the top. Both work great and they sure beat a regular block of wood. I keep one handy to knock off any rough edges if I use a hand saw to cut a board to length. You can make several and keep different size grit sanding blocks at your fingertips.

7 comments so far

View trotter's profile


33 posts in 3433 days

#1 posted 07-30-2010 03:41 AM

Jolly good Dyno. Good improvement.
I have something similar, and have added a thin layer of cork between te block and the sandpaper
this seems to give a slightly more flexible surface.

-- I wish I could sell my experience for half the price it has cost me.

View Brandon's profile


4152 posts in 3314 days

#2 posted 07-30-2010 09:02 AM

excellent idea! I’ll have to make one of these sometime. Thanks for sharing.

-- "hold fast to that which is good"

View mafe's profile (online now)


11972 posts in 3451 days

#3 posted 07-30-2010 02:58 PM

Really nice idea to make it ergonomic, I will do some like this with no doubt.
Thank you.

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View swirt's profile


3873 posts in 3334 days

#4 posted 07-30-2010 03:22 PM

Clever design.

-- Galootish log blog,

View brunob's profile


2277 posts in 4532 days

#5 posted 07-30-2010 03:43 PM

I like it. Thanks.

-- Bruce from Central New, if you'll pardon me, I have some sawdust to make.

View cwdance1's profile


1159 posts in 3621 days

#6 posted 07-31-2010 02:44 AM

Great Idea!!!

View GabrielX's profile


231 posts in 3194 days

#7 posted 09-02-2010 05:52 PM

Now, why did I buy this power sander?? Awesome plans, thanks!

-- GX

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