Handy sanders use every bit of the grit
A firm, flat sanding block ensures flat surfaces on your project. Here’s how to make your own sanding blocks and paddles that utilize an entire 9×11" sheet of sandpaper.
Start by cutting four hardwood sanding blocks to the dimensions shown. Wrap each block with packing tape. To ensure a smooth sanding surface, don’t overlap the tape.
Cut four 41⁄2" squares from a sheet of sandpaper and cut the remaining piece into two 1"-wide strips. Apply spray adhesive to the tape-wrapped blocks and the back of the sandpaper squares, then wrap the paper around the faces and edges of the blocks.
To utilize the 1" strips, I make 1×8" sanding paddles from 1⁄8" plywood and wrap the 1" strip around the end. I mark each paddle with the grit of sandpaper used. When the sandpaper wears out, remove both the paper and tape to avoid adhesive buildup. Repeat the process with fresh materials.