The simple sanding stick has been done time and again by woodworkers, but I thought I’d take a different approach and make something more permanent. The idea was to make these very much like regular metal working files, with a handle that’s comfortable to hold and use. Like metal files, these would be hung up and used when needed, and not used once and thrown away like the typical sanding stick. When the grit wears out on the sandpaper, it can be replaced.

I decided to make a set of three that are bigger and started by cutting the blanks from hardwood. I used a metal file with a handle that I like to draw the handle shape on the blank and then cut that out:

I also rounded over the edges of the handle and drilled a hole for hanging it up.

I used double sided tape to adhere the sandpaper. This can be removed fairly easily when the sandpaper wears out. As for the sandpaper itself, I used good quality aluminum oxide and the file has 100 grit on one side, and 60 grit on the other:

Of course any number of these could be made in several different grits and sizes and shapes.

The next one is a special shape. It’s concave on one side and convex on the other. To cut the concave side I set up an angled fence on my table sat to run the stock diagonally over the blade to cut the cove:

This operation is shown in more detail in the video at the bottom of this page.

Hard to say how often I would use this, but it’s nice to have on hand if I do need it.

The last in this set of three is a round one that I made from a 1″ dowel:

Again, I just used double sided tape to attach the sandpaper. While spray glue would also work, it might be harder to remove the sandpaper after it wears out.

I hung the up on the side of my drill press cabinet and have used them several times since, especially the flat one:

Here’s a video showing how I made these: