Corner Sanding Block: An Easy Jig for Rounded Corners
Rounding the corners of a woodworking project is easy enough with a band saw. But cleaning up the saw marks afterward can be a challenge, especially when you want the curved edge to remain square to the face of the workpiece.
That's where this simple shop-made corner sanding block comes in.
Woodsmith reader Mike Stuart of New Brighton, Minnesota, came up with a handy sanding jig made from just two pieces of plywood. It's easy to build, inexpensive, and makes smoothing rounded corners a lot more predictable.
Make the Sanding Block from Two Pieces of Plywood
The jig consists of two plywood pieces glued face-to-face.
The larger piece acts as a guide, riding against the face of the workpiece to keep the sanding surface square to the edge.
The smaller piece, about half the size of the larger one, provides the sanding surface.
Before gluing the two pieces together, cut a shallow groove in the larger piece just ahead of where the smaller block will sit.
This groove serves two purposes. It allows the sandpaper to extend across the entire sanding edge, and it provides a little clearance for sanding dust.
Once the groove is cut, glue the plywood pieces together, keeping the sanding edge square to the guide.
Add Sandpaper and Smooth the Corner
To use the jig, cut a strip of adhesive-backed sandpaper to fit the exposed sanding edge of the smaller plywood block.
After rough-cutting the corner at the band saw, position the larger guide against the face of the workpiece.
Then move the block along the rounded corner to remove the saw marks and smooth the curve.
The larger plywood guide helps keep the sanding edge square as you work, making it easier to maintain a consistent shape.
When the sandpaper becomes worn, simply peel it off and replace it with a fresh strip.
A Simple Solution for Better Rounded Corners
This corner sanding block is a good example of how a small shop-made jig can make an everyday woodworking task easier.
With just a couple of plywood scraps and some adhesive-backed sandpaper, you can create a handy tool for smoothing curved corners while maintaining square edges.
It's a simple addition to your sanding supplies that can save time whenever you're cleaning up rounded corners on a project.
More Finishing & Sanding Tips
Getting a smooth surface and a beautiful finish doesn't have to be a tedious process. Sometimes, a few simple tricks can save time, reduce frustration, and help you get better results.
Explore our Finishing & Sanding Tips & Techniques for practical, shop-tested ideas that make woodworking easier. From clever sanding jigs and techniques for smoothing tricky surfaces to helpful finishing tips, you'll discover ways to work more efficiently and give your projects a professional-looking finish.
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