Small sanding block with rubber grip

What is it?

40 mm wide sanding block.

With rubber grip on the sides and the knob

Embedded nut inside for bolt to griping a sand paper.

Glued paper foam around the surface to make sanding more even.

Why make it?

This is a remake and a mix of multiple designs that has couple improvements and mainly a redesign using FreeCAD.

Original idea is from https://www.thingiverse.com/thing:4822825 made by Perinski and his improved V2 https://www.thingiverse.com/thing:4823204 . There are multiple similar designs all over (like https://www.printables.com/model/87618-sanding-block by  zbynek) but I believe Perinski had the original idea.

Besides the size and shape the best part about Perinskis design was the rubber grip on the sides and the knob but I had issue with self tapping screws or inserting nut from the side and since it's better to print this design split in half it's better to glue and embed the nut inside too.

BOM

3D printed

Grip pieces should be printed out of flexible material and it's best to be as soft as possible. I used Extrudr Flex medium.

• 1x Block - Splint into two sides
• 1x Clip - to grip the sand paper
• 1x knob - to screw that grips the bolt head
• 1x knob cap - to hide the bolt head
• 1x knob grip - printed of soft flexible material for better grip
• 2x grip piece - soft flex material, two design options included

Hardware

• 1x M5 nut
• 1x M5 14-20 mm bolt hexagon head
• PaperFoam

Super glue or other adhesive to glue in the block sides and grips.

Assembly

1. Glue both block sides with M5 nut inside
   1. Apply glue on the sides. You can add a drop in location of a nut but not too much so the glue does not get into the threads of the nut
   2. Insert nut into position. Can use bolt together with the nut to help positioning and to keep pieces together while gluing
   3. Add other side on top and hold until glue cures
2. Test to make sure the nut threads are not glued
3. Cut paper foam to size ~150x40mm .
4. Glue paper foam to the block. If you have paper foam, it's great but even then I just added extra glue.

   5. Glue both flexible grip inserts

   6. Glue the bolt into the knob piece, then glue the cap and the grip

  7. Add the sand paper of your choice. It should be ~165mm length