Sanding Block - Prototype

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Project by MikeB_UK posted 12-18-2017 09:54 AM 1719 views 4 times favorited 5 comments Add to Favorites Watch

I decided to try and make a slightly improved sanding block.

As always feel free to give comments, advice, insults etc :)

I started off with the usual design and added a overhung top for grip and a star knob for ease of use and comfort in the palm.
Wood used is what I had lying around so body is walnut, top and sides are a sappy teak and the knob is beech.

Gone with a 5 layer design, mostly because I had a fair bit of 10mm ish thick wood lying around, partly because it means you can drill the hole all the way through each piece.

So, grab some scraps, mark them up and drill the holes for the bolt through all of them.

Chisel a hole to fix the bolt head to the bottom piece

Cut the hole for the knob in the top 2 pieces and glue together.

Add the sides on to the bottom, realise you’ve made them way too high and plane them down to about 3-4mm above the bottom

Cut out 2 circles for the knob (2nd gets glued on top of this when nut fitted)

Chisel out a space for the nut

Add the nut and glue the second circle on top.

Make the star knob (Jig shamelessly copied from somewhere on this site, can’t remember who did it or I’d give a link), need to make a decent jig at some point but threw this one together from a bit of 2×4 and it worked OK.

As the knob is just 3 bits of wood glued together I figured it might get a lot of sheering stress so drilled some holes for some rod to strengthen it.

Epoxy the rod in and clean it up.

Tidy up, the block has been over-length to allow for modifications at this point, so cut the sides so it fits the sandpaper roll.

Add some cork to the bottom

A coat of danish oil and a couple of coats of varnish and I’m good to go.

I’ll see how the extra grip and star knob work in real life for the next month or so.

-- If I say I'll fix something around the house I will, there is no use nagging about it every 6 months.

5 comments so far

View splintergroup's profile


3631 posts in 1952 days

#1 posted 12-18-2017 10:03 PM

Lots of work, especially that knob!

There are a zillion ways to make a sanding block, but this one looks comfortable and obviously really locks down the paper.


View jeffswildwood's profile


4428 posts in 2707 days

#2 posted 12-19-2017 12:45 AM

Nice job Mike! This is one of the projects I need to do but never seem to get around to it.

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View SuperCubber's profile


1109 posts in 3014 days

#3 posted 12-19-2017 01:43 AM

Cool sanding block! Is this the template you were referring to?

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

View whistlingwoodies's profile


43 posts in 1751 days

#4 posted 12-19-2017 02:28 AM

Cool way to make the knob.

View MikeB_UK's profile


154 posts in 1764 days

#5 posted 12-19-2017 09:33 AM

Cheers all, top 3, must be a slow day :)

No, not a template, it was a jig fairly similar to mine – But better made, obviously :)
Maybe I saw it elsewhere.

-- If I say I'll fix something around the house I will, there is no use nagging about it every 6 months.

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