Jump to content
Sign in to follow this  
stefanwest

Custom Flexible Sander

Recommended Posts

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.

 

IMG_0577_zpsf71150a2.jpg

 

Started the bending.

 

IMG_0578_zpsb1ef06a9.jpg

 

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

 

IMG_0579_zps7b5ee3ac.jpg

 

Made my cuts to even out the arms.

 

IMG_0580_zpsab829a69.jpg

 

Clean out the cut and enlarge it.

 

IMG_0581_zps1685344f.jpg

 

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

 

IMG_0582_zps2c443f25.jpg

 

Glued the rivet heads to the short tube sections.

 

IMG_0583_zpsa3e6a0d9.jpg

 

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

 

IMG_0584_zpsb937243e.jpg

 

Cutting my own sanding strips.

 

IMG_0585_zpsd49ad2f2.jpg

 

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.

 

IMG_0586_zps99c6547d.jpg

 

Write the grit number.

 

IMG_0587_zps1eda711b.jpg

 

Sander is done.

 

IMG_0588_zps1e8d705b.jpg

 

Testing it out. Works great.

 

IMG_0589_zps3c01fad6.jpg

 

Share this post


Link to post
Share on other sites

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.

Share this post


Link to post
Share on other sites

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).

Share this post


Link to post
Share on other sites

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.

Share this post


Link to post
Share on other sites

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.

Share this post


Link to post
Share on other sites
Sign in to follow this  

×
×
  • Create New...