DIY Sanding Blocks: Simple Shop-Made Sanding Tools
A good sanding block is one of the most useful tools you can have in your workshop. It provides better control than sanding with a loose sheet of sandpaper and helps create smooth, consistent surfaces.
While there are plenty of commercial sanding blocks available, I've found that some of the best are the ones you make yourself.
In fact, a few scraps of plywood, hardboard, or dowel stock can be turned into DIY sanding blocks that are perfectly suited to the job at hand.
Whether you're easing sharp edges, smoothing inside curves, or preparing a flat surface for finishing, these three simple sanding block designs will help you get better results.
1. Simple Scrap-Wood Sanding Blocks
The easiest sanding blocks to make are nothing more than small pieces of plywood or hardboard.
I keep a collection of these blocks in different sizes and shapes so I can grab the one that works best for a particular task.
They're especially useful for final touch-up work and sanding in tight spaces where a larger sanding block would be awkward.
Because these blocks are intended for light sanding rather than heavy stock removal, I generally use them with fine-grit sandpaper.
Use a Small Sanding Block to Ease Sharp Edges
One of my favorite uses for a small sanding block is breaking sharp edges.
A few light strokes along the corner of a board create a subtle chamfer that makes the edge more comfortable to handle.
Think of this small block as a sandpaper version of a block plane.
It provides excellent control when working along edges, in corners, or around small project details.
Attach Sandpaper with Adhesive
To prepare these blocks, I apply a piece of adhesive-backed sandpaper to one face.
Then I use a utility knife to trim the sandpaper flush with the edges of the block.
Keeping the abrasive flush allows you to sand right up to an adjacent surface without scratching it with an overhanging edge of sandpaper.
Adhesive-backed sandpaper is easy to replace when it wears out.
You can also use ordinary sandpaper with a light-duty spray adhesive. This provides enough holding power for sanding while allowing the worn paper to be peeled off and replaced.
2. Dowel Sanding Blocks for Curved Surfaces
Flat sanding blocks work well for straight edges and flat surfaces, but they're not much help when sanding inside curves or rounded profiles.
For those situations, I reach for a short length of wood dowel.
A dowel wrapped with sandpaper acts like a hand-powered sanding drum, making it easy to smooth curved surfaces without flattening their shape.
Choose the Right Dowel Diameter
The key to getting good results is selecting a dowel that matches the curve you're sanding.
I like to use the largest diameter dowel that will comfortably fit into the curve.
A larger dowel provides better support for the sandpaper and follows the shape more consistently.
It also reduces the chance of creating small dips or divots in the surface.
Keep several dowel sizes on hand so you can match the sanding block to different curves and radii.
Wrap the Dowel with Sandpaper
You can attach sandpaper to the dowel with spray adhesive, just as you would with a flat sanding block.
However, for most jobs, I find that simply wrapping the paper around the dowel and pinching the loose ends together works just as well.
This makes it easy to change grits or replace the paper without any adhesive.
These simple dowel sanding blocks are particularly useful for smoothing curved furniture parts, refining inside radii, and removing minor tool marks from rounded surfaces.
For more ways to handle challenging shapes, check out our guide to sanding curved wood, profiles, and contours.
RELATED ARTICLE: How to Sand Curved Wood, Profiles & Contours
3. Build a Quarter-Sheet Sanding Block
For sanding larger, flat surfaces, I prefer a more substantial sanding block.
This shop-made design is built from a scrap of dimensional lumber and accepts a quarter sheet of sandpaper.
It offers a comfortable grip, a cushioned sanding surface, and a simple way to secure and replace the abrasive.
A Comfortable Handle for Hand Sanding
The top of the block is shaped to fit comfortably in your hand.
This makes it easier to maintain consistent pressure while sanding larger surfaces.
The block is sized to accept a quarter sheet of sandpaper, making it convenient to use standard sheets without much waste.
A Simple Sandpaper Clamping System
Instead of using adhesive, this sanding block holds the paper mechanically.
One end of the sandpaper slips into a saw kerf at the back of the block.
A hardboard clamping pad and knob secure the paper in place.
The sandpaper wraps around the front of the block, allowing the rounded nose to reach into tight areas and work along gentle curves.
When the paper wears out, simply loosen the knob, remove the old sheet, and install a fresh one.
Add Cork for Better Sanding
The bottom of the sanding block is lined with cork.
The cork provides a slightly cushioned surface beneath the sandpaper, helping distribute pressure and allowing sanding dust to clear more easily.
It also helps extend the useful life of the abrasive.
I liked this sanding block enough that I made two of them. That way, I can keep different grits of sandpaper ready to go without constantly changing sheets.
Make this comfortable, reusable sanding block for your workshop. The shop-made design features a shaped wooden handle, cork sanding surface, and convenient clamping system for quarter sheets of sandpaper.
GET THE FREE STEP-BY-STEP PLANS → Build Your Own Sanding Block
Which DIY Sanding Block Should You Use?
Each of these shop-made sanding blocks has its place in the workshop.
A small plywood block provides precise control for detail sanding and easing sharp edges.
A dowel wrapped with sandpaper works well for inside curves and rounded profiles.
And a larger quarter-sheet sanding block is a comfortable choice for smoothing flat surfaces and preparing projects for finishing.
The nice thing is that none of these tools requires much material or time to make.
With a few scraps and some sandpaper, you can build a collection of homemade sanding blocks that will come in handy on almost every woodworking project.
Sometimes the simplest shop-made tools are the ones you reach for most often.
How to Sand Curved Wood, Profiles & Contours
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.
EXPLORE SANDING TOOLS & TECHNIQUES → Make Sanding Tricky Shapes Easier
