A simple sanding block is the best tool to use for smoothing or flattening a plain board, but what if you want to get that same flattening effect on a contoured surface like a piece of decorative molding?
To create a good contour sanding tool, nothing beats a block of rigid foam insulation.
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One way to create a custom sanding block is to trace the molding outline or profile onto the end of the foam insulation block. A piece of double stick carpet tape applied to your work surface is a great way to hold the foam insulation in place while you work on it.
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| Extend the lines back along the face of the block as guides.
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| A simple tool called a micro plane, which is actually a very fine and very sharp rasp, works perfectly for shaping the foam insulation.
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| The result should be a contoured foam block that matches the molding you want to sand.
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| Once the block is contoured, just wrap sandpaper loosely around the block so that it can easily conform to the profile. Set the sanding block on the molding and begin to sand.
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| Note: If you don't happen to have a set of micro rasps on hand then here's another method of shaping that rigid foam insulation. |
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| Begin with a scrap piece of molding identical to the one you want to sand, and a piece of sandpaper. Apply spray adhesive to the back of the sandpaper and to the molding.
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| Once the surface is tacky, stick the sandpaper onto the molding, grit side up. Use a putty knife to press the sandpaper into the grooves and crevices.
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| Next, take a foam block, set it squarely on top of the sandpaper covered molding and begin moving it back and forth. The molding shape will quickly transfer to the foam giving you an exact duplicate of the molding profile.
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| You can either loosely hold the sandpaper on the foam block, or you can once again apply a spray adhesive to the contoured foam block and the back of the sandpaper to create a more secure attachment and eliminate the chance of slipping.
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| After trimming off any excess paper, you are ready to sand.
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| With a piece of rigid foam insulation, some sandpaper and spray adhesive, you can make a custom sanding block that will fit just about any piece of molding.
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