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User-Friendly Sanding Blocks

T

O MAKE HAND-SANDINGless tiring, our class at Anderson Ranch
Arts Center analyzed and redesigned the common sanding
block. After experimenting with a variety of materials and thicknesses,
the consensus was that a relatively thick (1 in. to 1^1 ⁄ 4 in.) block lami-
nated from hefty Finply or Baltic-birch plywood is the most comfort-
able. We glued^5 ⁄ 32 -in.-thick sheet cork, available from any building-
supply store, to one side of slightly oversized blanks. Then we trimmed
the blocks with the corkside up to reduce tearout.
Opinion was split on whether the blocks should be narrow or
wide. To satisfy everyone’s ergonomic needs, we came up with the two
sizes shown in the drawing above. Each one uses a one-quarter sheet
of sandpaper. After the blocks were cut to size, we sliced shallow
V-grooves (finger holds) in both long edges of the blocks on the table
saw. Finally, we rounded the corners and then lightly sanded all
the surfaces.

CHAPTER SEVEN

Cork

pads, 5

⁄ 32 in.

25 ⁄ 16 in.

27 ⁄ 8 in.^4

(^7) ⁄ 16 in.
Tilt table saw
blade 14° to
cut V-groove
for finger hold.
Baltic-birch
57 ⁄ 16 in. plywood blocks
11 ⁄ 4 in.
11 ⁄ 4 in.