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Custom Flexible Sander


stefanwest

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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.

 

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Started the bending.

 

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Add CA glue and let it run into the corner to give some extra strength.

 

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Made my cuts to even out the arms.

 

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Clean out the cut and enlarge it.

 

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Cut smaller pieces off the smaller tube and selected couple rivet heads.

 

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Glued the rivet heads to the short tube sections.

 

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Using no glue I just forced the smaller tube sections onto the ends of the sander.

 

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Cutting my own sanding strips.

 

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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.

 

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Write the grit number.

 

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Sander is done.

 

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Testing it out. Works great.

 

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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).

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