Popsicle Sanding Stick




About: I enjoy everything

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
Spring clamps
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.



    • Gardening Contest

      Gardening Contest
    • Colors of the Rainbow Contest

      Colors of the Rainbow Contest
    • IoT Challenge

      IoT Challenge

    18 Discussions


    2 years ago

    This is an awesome idea. I do work with Fimo and sculpy clay for jewelry, and its recommended i sand the pieces, so now i can use these to get into tighter spots

    1 reply

    3 years ago

    I have some really tight spots I need to start out with 80 grit, so glad I ran across this simple and very functional idea. Thanks

    1 reply

    4 years ago on Introduction

    Can also use Tongue depressors, paint sticks (for 1 gal and 5 gal stirring) to get various sizes and stiffness for different projects. For bigger sticks try self adhesive hook velcro to use velco backed sandpaper.

    1 reply
    Fikjast Scottrupin.chheda

    Reply 5 years ago

    Thank you for the kind words and viewing my instructables


    5 years ago on Introduction

    Good idea. 32 years ago I needed a rasp, but when I went to buy it, came back home without it. Then I bought a thick waterproof sandpaper sheet, and made a good rasp with it and a 30 cm long stick. It lasted until now.

    1 reply

    Great comment, this is why I like instructables. I usually work on projects that can fit in my hand; you opened my eyes towards using this on larger applications. Not that I would take advantage of it, but my local paint supply gives away free paint stir sticks – standard and large. These paint sticks would work great (probably with a ½ sheet).


    5 years ago

    I also use Popsicle sticks but the ones I use appear to be a little wider than yours. You should try double-sided tape. I'll trace the Popsicle on the sand paper and then cut it out. I put enough tape on the stick to cover it and then place the paper over it. It works well. It's nice because when the paper gets used up you can still use the stick and just put another piece on.

    1 reply
    Fikjast Scottfaybrown

    Reply 5 years ago

    Thank you for viewing and providing a comment on my instructables.
    This is what makes instructables so great

    No problem, if I work the correct grit for the application, it works fine. The biggest problem I have is with the quality of the paper. I say sand paper; I mostly use emery paper. The poor quality paper tends to split. Please note, I work on hobby items, like jewelry, wood carving, model making. By shorting the wrap-around step, you can really tighten the paper on to the stick. I tend to keep my finger on top which also helps pinch the paper. Thanks for the question and viewing my instructables. Scott

    Thank you for your comment; I have some in all of my tool boxes.
    Your feedback is why I like instructables.
    In working with different metals I use 60 80 100 150 220 280 320 400 600 1000 1200 1500 grits.

    Warmly Scott