How to Make Sandpaper Strips Last Longer With Duct Tape
Sanding curved surfaces, rounded edges, and wood turnings can be challenging with a standard sanding block. Sometimes the easiest solution is to cut a narrow strip of sandpaper and use it like a flexible sanding belt.
The problem is that ordinary sandpaper strips don't always hold up. The paper backing can tear or wear out long before the abrasive loses its cutting ability.
Fortunately, there's a simple way to make sanding strips stronger and more durable using something you probably already have in your shop: duct tape.
This clever woodworking tip comes from Woodsmith reader Henry Whitmer of Runnells, Iowa. By reinforcing the back of sandpaper with heavy-duty duct tape, you can make custom sanding strips that resist tearing and last longer.
In the video, Phil demonstrates how to make these reinforced sanding strips and put them to work on curved woodworking projects.
Why Sandpaper Strips Tear So Easily
Narrow strips of sandpaper are especially useful for smoothing rounded surfaces and curved parts.
By holding the ends of a strip and pulling it back and forth across a workpiece, you can sand contours that would be difficult to reach with a sanding block.
However, most standard sandpaper has a paper backing that isn't designed to withstand repeated pulling and bending.
As you work the strip back and forth, the backing can weaken and eventually tear.
Often, the abrasive is still sharp when the strip breaks. That means you're throwing away usable sandpaper simply because the backing failed.
The solution is to reinforce the paper before cutting it into strips.
Reinforce Sandpaper With Heavy-Duty Duct Tape
The trick is simple: Apply duct tape to the back of a sheet of sandpaper before cutting it into strips.
The tape adds strength to the paper backing, helping prevent it from tearing during use.
Because you can cut the reinforced sandpaper to any width, it's easy to make sanding strips suited to the shape and size of your workpiece.
You only need a few common supplies:
- Sheet sandpaper in your preferred grit
- Heavy-duty duct tape
- Ruler or straightedge
- Utility knife
- Cutting mat or scrap board
How to Make Reinforced Sandpaper Strips
Step 1: Apply Duct Tape to the Back
Start with a sheet of sandpaper and turn it over so the paper backing faces up.
Apply a strip of heavy-duty duct tape to the back of the sandpaper.
Press the tape firmly into place, smoothing out any wrinkles or air bubbles.
The tape reinforces the backing and helps the sandpaper withstand repeated bending and pulling.
Step 2: Cut the Sandpaper Into Strips
Place the sandpaper on a cutting surface with the abrasive side facing down.
Use a ruler or straightedge and a sharp utility knife to cut the reinforced sandpaper into strips.
Cut through both the paper backing and the duct tape.
You can make the strips as wide or narrow as needed for the sanding task.
Step 3: Sand Curved and Rounded Surfaces
Once the strips are cut, they're ready to use.
Hold one end of the reinforced strip in each hand and wrap the abrasive side around the curved workpiece.
Move the strip back and forth with steady, even pressure.
The flexible strip conforms to the shape of the wood, while the duct tape backing helps prevent tearing.
This makes it easier to sand rounded parts without constantly replacing broken strips.
Where Reinforced Sandpaper Strips Work Best
This technique is particularly handy for woodworking projects with rounded or curved details.
Sanding Curved Furniture Parts
Chair legs, curved rails, and shaped furniture components often have contours that are difficult to sand with a flat sanding block.
A flexible strip wraps around the surface, allowing you to smooth the curve while following its shape.
Smoothing Roundovers and Rounded Edges
Reinforced sanding strips also work well for smoothing rounded edges and profiles.
The narrow strips make it easier to work along a curved surface without sanding a large surrounding area.
Sanding Wood Turnings
Spindles and other turned parts can also benefit from flexible sanding strips when worked by hand at the bench.
The strip conforms to the rounded profile, helping smooth the surface evenly.
For lathe work, follow appropriate sanding and machine-safety practices. Avoid wrapping abrasive around a rotating workpiece or allowing a strip to catch and pull your hands toward the turning.
Tips for Getting More From Your Sandpaper
A few simple details will help you get the most from these reinforced sanding strips.
- Use heavy-duty duct tape. A strong tape provides better reinforcement for the paper backing.
- Apply the tape before cutting. It's easier to reinforce a full sheet than individual narrow strips.
- Choose the right strip width. Narrow strips work well for tight curves, while wider strips provide more coverage on broad rounded surfaces.
- Use the appropriate grit. Start with a coarser grit when shaping or removing tool marks, then move to finer grits for smoothing.
- Keep the pressure even. Let the abrasive do the work rather than pulling excessively hard on the strip.
- Replace worn abrasive. The reinforced backing may last longer, but the sandpaper still needs to be replaced once it stops cutting effectively.
A Simple Way to Make Sandpaper Last Longer
Sometimes the best woodworking tips are the simplest.
Adding a strip of duct tape to the back of sandpaper takes only a few seconds, but it can make a noticeable difference when sanding curves, rounded edges, and other shaped parts.
The reinforced backing helps prevent the sandpaper from tearing before the abrasive wears out. And because you can cut the strips to any width, it's easy to customize them for the project at hand.
It's an inexpensive shop trick that helps you get more use from your sandpaper while making curved-surface sanding a little easier.
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