This is my version of a sanding stick. I see a lot of sanding sticks that you permanently glue the sand paper onto the stick. I wanted something that I could change out, when the paper wears down.
Step 1: Items Used
Popsicle sticks – 2 sticks per sanding stick. I used a 3/8 inch wide – 1/16 inch thick - 4 ½ inch long
Yellow wood glue
Sand paper – I used 100-grit and 280-grit Plastic
drop cloth – I used a plastic grocery bag
Marker – used for labeling the stick
Step 2: Glue the Sticks Together
I put just a drop of yellow glue on the end of one Popsicle stick. I used my finger to spread the glue approximately ¾-inch on the strick. I put the
other stick on top of the glued stick. I lined them up and put a spring clamp on the
end with the glue.
I try and make more sanding sticks than I need; since I am already set up and have everything out.
I put plastic down to have a place for the sticks to rest while drying.
I let them dry overnight.
Step 3: Size the Paper on the Stick
I ripped down my large sheets of sandpaper down to ¼ sheet size, for ease of handling.
I put the paper in between the two sticks.
I keep folding it over (or around the two sticks). You are going to wrap over the flats 3 times.
Step 4: Rip the Paper to Size
I just rip the excess paper down the side of the sticks.
Step 5: Slide Out and Slide In
The sticks need to slide out of the folded paper.
Then the last or ripped side of the paper needs to be folded back into the middle. See diagram.
Now the glued sticks need to be slid back in, pinching the paper.
Step 6: Finish by Labeling
Now the Popsicle Sanding Stick can be labeled with the grit of the paper used.
I used a permanent marker to put the number on the open wood handle of the stick.
The tail or the end of the paper that is not actually on the stick can either be left on or cut off.
I am pleased that the master silversmith that I study under, still uses the sanding sticks that I made him.