stefanwest Posted January 18, 2014 Report Share Posted January 18, 2014 I have in my tool chest the flexible sander to help sand curved surfaces. But for me this tool is too wide. I saw somewhere where someone made there own custom flex sander. So I cannot take credit for this idea. But I gave it a try and made my own. Only difference is the one I made is narrower so it would be more comfortable in my hand and I am able to get into tighter places. First I bought tubing benders, cutter, tubing and small leather rivets. Tube sizes are 3/16 and 5/32. Started the bending. Add CA glue and let it run into the corner to give some extra strength. Made my cuts to even out the arms. Clean out the cut and enlarge it. Cut smaller pieces off the smaller tube and selected couple rivet heads. Glued the rivet heads to the short tube sections. Using no glue I just forced the smaller tube sections onto the ends of the sander. Cutting my own sanding strips. Add couple drops of CA glue. When gluing the other end I slight squeeze the sander so it can get a tight grip on the sand paper. Write the grit number. Sander is done. Testing it out. Works great. Link to comment Share on other sites More sharing options...
Rusty White Posted January 18, 2014 Report Share Posted January 18, 2014 Well done and very clever. However, isn't that brass tubing pretty soft? Have you had any problems with it bending during sanding sessions? Just curious. Link to comment Share on other sites More sharing options...
AZKevin Posted January 18, 2014 Report Share Posted January 18, 2014 Nicely done and well made. But by the time you buy all the tools, supplies, and invest the time isn't the Flexi-file set up just as good and inexpensive?? Please don't misunderstand, I'm not trying to disparage your work here (I like making my own tools as well), a set of 4 flexi-files, 5 place file holder and 24 sanding strips (150, 280. 320, 400, and 600 grit) runs about $40. A single flexi-file and 17 assorted sanding strips runs about $12. I use mine on all curved surfaces (fuselage seams and wing leading edges especially). Link to comment Share on other sites More sharing options...
stefanwest Posted January 18, 2014 Author Report Share Posted January 18, 2014 Total cost of the materials not counting the benders and the cutter is about $6.00 and I can make 2 to 3 sanders depending on size. The flexi-file costs about $18.00 for one file. Link to comment Share on other sites More sharing options...
stefanwest Posted January 18, 2014 Author Report Share Posted January 18, 2014 The brass tubing has the same feel amd strength as the flexi-file I have. Course this was my first attempt and I could have bend the first curve alittle wider and not have suck a kink in it. Link to comment Share on other sites More sharing options...
Recommended Posts