How to Make a DIY Sanding Block from Scrap Wood
A good sanding block makes hand sanding easier, more comfortable, and more effective. While you can simply wrap sandpaper around a scrap of wood, a well-designed sanding block offers better control, a secure grip, and a flat sanding surface that helps produce consistent results.
This DIY sanding block takes that idea a step further. Its comfortable handle, tapered sides, and clever sandpaper clamping system make it a practical addition to any woodworking shop. Best of all, you can build one from a few pieces of scrap lumber using basic woodworking tools.
In the video, Woodsmith's Phil Huber demonstrates how to build this shop-made sanding block, from shaping the wooden body at the band saw to installing the adjustable sandpaper clamp and cork sanding surface.
Want to build one for your shop? Download the FREE Sanding Block Plans for the complete pattern, dimensioned drawings, and step-by-step instructions.
Why Build Your Own Sanding Block?
There are plenty of commercial sanding blocks available, but making your own allows you to incorporate features that make hand sanding more comfortable and efficient.
This custom sanding block has several advantages over a simple block of wood:
- Comfortable handle: The curved opening provides a secure grip and reduces hand fatigue during long sanding sessions.
- Lightweight construction: Pine or other softwood keeps the block easy to handle.
- Tapered sides: The angled body allows you to sand close to adjoining surfaces without scraping your knuckles.
- Secure sandpaper attachment: A clamping pad and retaining slot hold standard sandpaper firmly in place.
- Versatile design: The block accommodates both standard quarter-sheet sandpaper and adhesive-backed abrasives.
- Cork sanding surface: A thin cork layer provides cushioning beneath the sandpaper for smooth, consistent sanding.
The result is a simple woodworking tool that's comfortable to use and easy to customize.
Building the Wooden Sanding Block
The body of the sanding block consists of two pieces of wood. A 1/2"-thick piece forms the base, while a thicker piece creates the handle and upper body.
Pine is a good choice because it's lightweight and easy to shape. You can even use leftover construction lumber or other suitable scraps from your shop.
Cut the Handle and Shape the Body
Start by preparing the two blanks and transferring the sanding block pattern onto the wood.
With the pieces temporarily held together, trace the curved handle opening. Then head to the band saw to remove the waste and establish the inside shape of the handle.
A coarse rasp makes quick work of removing the band saw marks. Follow up with a half-round file and sandpaper to smooth the inside of the handle.
Once the handle opening is shaped, glue the base to the upper body.
After the glue dries, return to the band saw to cut the outside profile of the sanding block.
Taper the Sides for Better Clearance
One of the most useful features of this sanding block is its tapered shape.
Instead of having straight vertical sides, the block narrows toward the top. This provides additional clearance for your fingers when sanding close to a perpendicular surface, such as the inside corner of a cabinet or along a raised panel.
You can create the taper at the band saw without tilting the table.
Attach a narrow plywood spacer to the band saw fence with double-sided tape. The spacer tilts the sanding block slightly as it passes through the blade, creating the desired bevel.
Make a pass along each side to complete the tapered profile.
Make the Adjustable Sandpaper Clamp
A sanding block is only as useful as its ability to hold sandpaper securely. This design uses a simple clamping system at the front and a narrow retaining slot at the back.
Cut the Recess for the Clamping Pad
Near the front of the sanding block, cut a shallow recess to accept a hardboard clamping pad.
Start by making a series of closely spaced cuts at the band saw to define the recess. Then remove the waste with a sharp chisel.
A router plane is useful for leveling the bottom of the recess and creating a consistent depth.
Install the Threaded Insert and Clamp
The clamping pad is secured with a threaded knob that tightens into an insert installed in the wooden body.
Drill the hole for the threaded insert at the drill press, keeping the hole square to the bottom of the recess. Then install the insert.
Cut the clamping pad from hardboard so it fits within the recess. Drill a hole for the threaded knob, and the clamping assembly is ready to install.
A small strip of sandpaper on the underside of the pad provides additional grip to help prevent the abrasive from slipping during use.
The finished clamp makes it easy to tighten or release the sandpaper without complicated hardware.
Shape the Handle for a Comfortable Grip
With the clamping hardware installed, the final shaping focuses on making the sanding block comfortable to hold.
Use a rasp to round over the back of the handle and blend the angled sides into smooth curves. A file removes the coarse rasp marks, while sandpaper smooths the remaining surfaces.
Pay particular attention to the underside of the handle opening. Easing these edges makes a noticeable difference when using the block for extended periods.
The goal isn't a perfectly sculpted handle. It's a smooth, comfortable shape that fits naturally in your hand.
Add the Sandpaper Retaining Slot and Cork Base
The back of the sanding block uses a simple kerf to capture one end of the sandpaper.
Mark a line across the heel of the block and cut a shallow slot with a hand saw. A Japanese pull saw works well for this operation.
The slot only needs to be deep enough to hold the sandpaper securely. If necessary, widen it slightly so the abrasive slips into place without bunching.
To complete the sanding surface, add a thin layer of cork to the bottom of the block.
Adhesive-backed cork shelf liner works well and is easy to trim with a utility knife.
The cork provides a little cushioning beneath the abrasive, helping it conform to the work surface while maintaining the flat support needed for effective sanding.
How to Use Your Shop-Made Sanding Block
Installing sandpaper is straightforward.
For standard sandpaper, insert one end into the slot at the back of the block. Wrap the abrasive around the cork-covered bottom, then secure the opposite end beneath the front clamping pad.
Tighten the knob to hold the paper in place.
The block is also suitable for adhesive-backed sandpaper, giving you flexibility when choosing abrasives for different woodworking projects.
The flat base makes it useful for sanding panels, tabletops, and other broad surfaces. Meanwhile, the tapered sides and comfortable handle make it easier to work along edges and into tight corners.
Download the Free DIY Sanding Block Plans
Sometimes the most useful woodworking projects are the simplest ones.
This shop-made sanding block turns a few pieces of leftover lumber into a tool you'll reach for again and again. It's lightweight, comfortable, and designed to make hand sanding more efficient.
The project is also a great opportunity to practice basic band saw techniques, shaping with rasps and files, and installing simple hardware.
Ready to make one for your shop?
GET THE FREE STEP-BY-STEP PLANS - BUILD A BETTER SANDING BLOCK
Download the complete Woodsmith woodworking plans, including the pattern, dimensioned drawings, and step-by-step building instructions.
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Shop-made sanding blocks are great for everyday sanding tasks, but some curves, carvings, and intricate profiles call for a different approach.
Discover how sanding mops, flap wheels, and rotary tool accessories can help you smooth irregular surfaces and reach tight spaces that ordinary sanding blocks can't handle.
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