Simple Belt Sander Blocks

Handheld sanding blocks are a must for every woodworker. They allow you to easily hold sandpaper, remove unwanted material, and smooth projects. There are many commercially available sanding blocks, but these sanding blocks can be made quickly from scrap 2x4s and spare dowels. The block is split for about three-quarters of its length, and the belt is tensioned with a removable dowel.

With this design you can virtually create sanding blocks in any shape or angle you can think of. I have uploaded the dimensions of these two sanding blocks in both PDF downloads as well as the SolidWorks files used to create them.

The only materials you need for this project are:

• Scrap 2x4s
• 3/8 dowel
• Belt Sandpaper Size 3x21

Using either a band saw or table saw, rip lengthwise down the 2x4 till it's 3 inches wide and 9 5/16 inches long.

Using a 3/8 inch roundover bit, round the four ends of the block.

Drill a 3/8 inch hole 1 inch from one end and a 1/2 inch hole 7 inches from the same end. These holes will serve as a location to insert the dowel to create pressure across the sandpaper belt, and to disperse stress to keep the block from cracking.

Set up the fence to rout a 1/4 inch deep cut with a 1/2 inch radius starting and ending 1 inch from each end.

Cut an 1/8 inch wide slot through the dowel pin hole to the relief hole. This will bisect the sanding block and cause it to separate with the insertion of the dowel pin.

Cut 3/8 inch dowel to 3 inches in length. Sand a bevel on one end. Slide the sandpaper belt around the block. It should be mostly tight while sliding over the block. If it does not fit, cut a little more off the end of the block, re route the ends of the block and repeat as necessary until the sandpaper fits. If the sandpaper is loose, cut a new dowel pin with a larger diameter until sandpaper is tight.

Cut the width of the 2x4 down to 3 inches wide and 9 91/6 inches long. Cut a 45 degree angle on one end.

Drill a 3/8 inch hole 1 inch from one end and a 1/2 inch hole 7 inches from the same end. These holes will serve as a location to insert the dowel to create pressure across the sandpaper belt, and to disperse stress to keep the block from cracking.

Using a 3/8 roundover bit, router the top edge of the square end. Using a sander, roundover the 135 degree angle on the top of the sanding block.

Cut a 1/8 inch slot from the square end of the block through the dowel pin hole to the relief hole. This will bisect the sanding block and cause it to separate with the insertion of the dowel pin.

Set up the fence to rout a 1/4 inch deep cut with a 1/2 inch radius starting at 1 inch from one end to 7 inches in.

Cut 1/4 inch dowel to 3 inches in length. Sand a bevel on one end. Slide the sandpaper belt around the block. It should be mostly tight while sliding over the block. If it does not fit, cut a little more off the square end of the block, re route the ends of the block and repeat as necessary until the sandpaper fits. If the sandpaper is loose, cut a new dowel pin with a larger diameter until sandpaper is tight.

This was a quick and easy project that I originally found in the October 1999 copy of American Woodworker. You can view the publication here.