Shopmade sanding blocks


  • Shopmade sanding blocks

    Whilst cleaning up I found an old BT3central post by ejs1097 I printed out from a while back. I had forgotten about it.

    I made some changes and whipped out a few in a couple of evenings.
    What I liked about them was they hold the sandpaper tight and snug, the bought ones the paper works loose and sags and gets caught and tears.
    Also easy and cheap. Also has a square end for sanding into corners and a radius to do curves. I did modify the block so it used thicker stock (easier to hold) and put the paper retainers in the end rather than the top.

    I used a 2x4 Planed one side on the jointer so its dead flat and smooth, edge jointed, ripped to 2-5/8 inch wide. and then cut to 5-1/8" long blocks.

    Use a 1/2" brad point bit (I think that's important to keep from breaking out the side), 5/32" from the ends and 15/16" from the sanding face.

    Used a bull nose 1/2" bit 0.150" deep to cut finger grips on the sides, centered and 1" from the ends (3-1/8" center to center). Break the sharp edges of the slot with sandpaper for comfort.

    then used a roundover bit 1/2" R to cut the nose of one end, then a 3/16" roundover on the top to make it more comfortable to hold.

    Had some PVC tubing I cut to 2-1/2" long. Use 5/8" OD flexible PVC tubing (Available Lowes plumbing dept).

    Takes sandpaper sheets (normally 9x11), fold into fourths at 2-3/4 (fold parallel to the 9" side) and tear or cut to get four each 9 x 2-3/4" strips which work well with this size block. Now I can have spares, I make four pairs so I have 2 each of 4 sizes at hand.(100, 150, 220, 400 grit)

    Thought this article was worth resurrecting.

    View entire article and clarification discussion at
    Attached Files
    Last edited by LCHIEN; 06-28-2022, 01:54 AM.

    • LCHIEN
      LCHIEN commented
      Editing a comment
      Originally posted by chopnhack
      Thanks Loring for resurrecting this one and to the op! Very good stuff!!

      Loring, your design move the clamping tube to the front and rear edges of the block, did you find that change good or bad? I was thinking that one bad thing would be not being able to run right up to a corner, but on the plus side the tubing would act as a bumper.

      Or was your design just thicker than the op's and so the paper didn't wrap around the top?
      I made it thicker because I thought it would be easier to hold.
      I have not had the problem of the tubing keeping me from getting to a inside corrner. I guess you could make it shorter and wrap around the top but it would waste paper area. (or not, if you use the ends frequently.)

      If I recall I made the change to increase the length of the block a bit (I made mine 5-1/8 the OP was 4-7/8, I think I could have made mine at least another 1/4 or 1/2" longer). And because it was thicker and because I thought it looked better.

    • jseklund
      jseklund commented
      Editing a comment
      Great, now I have ANOTHER project to do. Those things would be so handy.

      That is some great work Lorring - kind of reminds me of some high end chisels

    • LCHIEN
      LCHIEN commented
      Editing a comment
      Bump this one. These are by far the best sanding blocks I ever used better than any commercial blocks. And super cheap and easy to make
    Posting comments is disabled.

Latest Articles


  • Small T-Nut for the Left side of Rip Fence and Front of Miter Fence on BT3x saws.
    by LCHIEN
    Small T-nut for the left side of BT3 rip fence or front of miter fence (Article Version)

    11-30-2023, 04:00 PM
    I have found a perfect T-nut for the front of the BT3 miter fence and for the left side of the rip fence (same extrusion used both places)

    Its actually a weld nut, but fits the T-slot described above.

    Weld Nut: #10-24 Thread, Tab, 1/32 in Base Ht, 3/8 in Base Wd, 5/8 in Base Lg, Steel, 50 PK
    Item 1LAJ3 Mfr. Model 1LAJ3​ (WW Graingers)...
    12-07-2023, 12:19 AM
  • Special DIY T-bolt for BT3000 Miter Fence, Rip Fence and Rails
    by LCHIEN
    After a bit more thinking, some universal T-bolts for the rip miter fence make more sense than fixture blocks.
    The two big slots in the rip fence and the miter fence and the front and rear rails are sized to take 1.00 inches wide x 1/8th and 1-1/8" wide x 1/8th.

    So I took some 1/8th flat Aluminum 1.00 inches wide and cut 1-1/8" long to make a 1" x 1-1/8" rectangular plates; I used a short rip fence Block to space the length but not cause a kickback with the...
    07-09-2023, 02:37 PM
  • How to make a BT3x00 Rip Fence/Miter Fence fixture block for mounting jigs
    by LCHIEN

    DIY BT3000 FIXTURE BLOCK for Rip/Miter Fence extrusion

    Simple shop construction - no machining.

    This is intended to fit the top T-track on the Rip and miter fence (uses the same extrusion) on the Ryobi BT3x00 / Craftsman 22811 family of saws
    You must make the Block and Base parts; you can make them 1.5" or 3 inches long or modify to any other length.
    Make the base from 1/8” aluminum bar, you can get 1.5”, 2”, and 3” at Lowes...
    05-24-2023, 09:55 PM
  • Another Thin Strip Jig
    by twistsol
    Ripping thin strips can be accomplished in a number of ways, but this jig is the best I've found so far.

    • There is no need to move the fence so every strip comes out exactly the same.
    • It is incredibly easy to build
    • It keeps your hands well away from the blade the whole time
    • It keeps control of the strip you are ripping all the way through the cut and past the blade
    • It doesn't interfere with the blade guard.
    • You can cut strips from any length of stock
    In the starting position,...
    04-16-2023, 10:42 AM
  • BT3000/BT3100 tall rip fence simple using fence clamps
    by LCHIEN
    BT3000 tall rip fence

    09-12-2021, 07:58 PM
    I have had a tall BT3000 fence for a number of years, I should have used it a few days ago but I didn't because it was too much trouble, And I paid the price as the tall item was a little unstable and I had a hard time controlling it as the two pieces separated and wallowed out a bigger kerf than I wanted at one place.

    Anyway the BT3000 tall fence is generally held on by the T-slots in the side of the rip fence. This is...
    10-20-2021, 03:27 AM
  • Extending rails/rail profiles
    by LCHIEN

    I am finally going to use my BT3000 extension rails.
    My objective is to have some easily attachable rail extensions rather than a full time wide BT3000 using two full rails taking up a lot of space and requiring table support under the right side as many do.
    I just want some wider support but not to do full 4x8 sheets of ply... if I need that, I'll break the sheet down on some sawhorses with a circ saw and some guides.

    I think I am going to cut my extension...
    08-14-2021, 11:32 AM

The SawdustZone Statistics


Topics: 61,323   Posts: 558,789   Members: 20,657   Active Members: 68
Welcome to our newest member, tinselbossy.

What's Going On


There are currently 2933 users online. 3 members and 2930 guests.

Most users ever online was 15,771 at 02:28 PM on 04-26-2024.