Carl’s Sanding Backup Pads

Photo: Carl's Sanding Backup Pads (sanding_backup_pads_blue)

Click here for a PRINTABLE version of the above blueprint.

I like Sanding Backup Pads (mandrels) that are thin, low profile and HARD. I add (attach) firm or soft foam interface pads to make them softer as needed.

I don't like thicker pads. Low profile pads are better at getting into the tight space between headstock and bowl.

I started making my own Sanding Backup Pads a couple of years ago when the price on commercially available ones went to $12. Way to much! I now just replace the velcro on my big collection of DIY sanding backup pads as needed. See Repair Worn Out Velcro below.

I make my backup pads out of 1/4" plywood and 1/4" flat head bolts.

I ALWAYS use a interface pad because it allows me to quickly switch between sandpaper grits. I have one FIRM and SOFT interface pad for each grit. See my Handy Sandpaper blog entry.

Notes:

1. Gripping the threaded part of the bolt in a drill chuck is not a problem. It works just fine.

2. If you are using interface pads to adjust the softness of pad then you don’t need and really don’t want a thick back up pad with lots of flex/foam.


Make Your Own

Photo: Make Your Own (sanding_bu_pads_11)

I make backup pads for 2" and 3" sandpaper.

I like my backup pads to be a little smaller than the interface pads. Thus, I really make 1-7/8" and 2-7/8" backup pads.

I layout 2" and 3" backup pads. They end up being 1/8" smaller after truing them up on the lathe and sanding the edges smooth.

Note: I normally make 6 new backup pads at a time. I keep a bin of new ones and worn out ones. The worn out ones need new velcro. I replace the Velcro when I run out of new ones. See Repair Worn Out Velcro below.

Photo: Layout and Drill 1/4 Layout and Drill 1/4″ Plywood

I layout 2" and 3" backup pads on good 1/4" plywood. Use a compass or template. See photo.

Drill a countersink hole for 1/4" flat head bolt. Then drill a 1/4" thru hole. See photo.

The countersink in the photo is a cheap and very common Vermont American one.

Photo: ROUGH Cut 1/4 ROUGH Cut 1/4″ Plywood

Use what every you have to ROUGH cut the circle. Cut OUTSIDE of the line.

I use my small wood cutting bandsaw. See my Small Wood Bandsaw bog entry.

Photo: Assemble with 5 Minute Epoxy (sanding_bu_pads_03) Assemble with 5 Minute Epoxy

I use a FULLY THREADED 1/4" by 20 flat head bolt that is 1-3/4" long from local hardware store. With a nut and washer.

The plywood will eventually just spin on the bolt if you don't put some 5 min epoxy in the joint. I put 5 min epoxy above the bolt head and below the nut to create a rock solid joint. See photo.

Photo: Make Plywood Round & Sand (sanding_bu_pads_06) Make Plywood Round & Sand

Turn the 1/4" plywood circle round on the lathe.

I use a drill chuck in the headstock with a 1/2" scrap of plywood jammed up against the backup pad on the tailstock side. See photo.

The 1/2" scrap of plywood prevents tears out. I turn it down to 1-7/8" or 2-7/8" on the first backup pad I make. Then, I use it over and over.

I use a 1/2" bowl gouge to turn the plywood round. Cut half way in from both sides to avoid tear out. Then use the 1/2" bowl gouge in scrapping mode to round the back side of the 1/4" plywood. See photo and my Blueprint.

I don't allow any sharp edges in my studio that can accidentally cut me. Thus, I sand the 1/4" plywood smooth with 120 grit sandpaper. Red Siasoft Sandpaper works good.

Photo: Purchase Hook Side Only Velcro (amazon_hook_and_loop) Purchase Hook Side Only Velcro

I purchase a 6" wide roll of Sew On "Hook Side Only" velcro from you guessed it. Amazon. See photo.

I attach the velcro with 5 min epoxy. Sticky back velcro is to wimpy for me. It does not work.

Google "6" Sew On Hook and Loop Fastner Hook Side Only"

Note: I like HARD backup pads. This makes finding velcro cheap and easy. I DO NOT need to find velcro with a firm or soft foam backing. I add (attach) interface pads to make them softer as needed.

Photo: ROUGH Cut Hook & Loop Velcro (sanding_bu_pads_04) ROUGH Cut Hook & Loop Velcro

I cut out 2" or 3" circles of velcro with scissors. Cut OUTSIDE the line. It should end up being a 1/4" oversize.

Remember, to ALWAYS use your wife's best sewing scissors in the shop! 🙂

Photo: Glue On Velcro (sanding_bu_pads_07) Glue On Velcro

Glue the velcro on with 5 min epoxy.

I spread the epoxy and plywood then clamp it in place with a scarp piece of plywood. Or glue up two at a time and clamp them back to back. See photo.

Photo: Trim Velcro to Finial Size (sanding_bu_pads_08) Trim Velcro to Finial Size

I mount the backup pad in the lathe with a drill chuck and trim the velcro down to match the plywood size with a spindle gouge.

I use a scrap of plywood that is bigger than the velcro on the velcro side to backup the cut. The scrap is just jammed in place by the tailstock. See photo.

Photo: Finished Backup Pad (Back Side) (sanding_bu_pads_09) Finished Backup Pad (Back Side)

Ready for use.

Photo: Finished Backup Pad (Front Side) (sanding_bu_pads_10) Finished Backup Pad (Front Side)

A thing of great beauty.


Repair Worn Out Velcro

Photo: Repair Worn Out Velcro (sanding_bu_pads_05)

Sooner or latter the velcro wears out and needs to be replaced.

Well, it wears out because I forget to put a piece of sandpaper on it before trying to sand with it. 😮 But, you are never going to do this!

When the velcro wears out, I remove it with a belt sander. See photo. Then I go thru the above process to glue on a new piece of velcro.

I have a big collection of DIY sanding backup pads. I keep a bin of backup pads with new velcro and a bin that are worn out. I replace the velcro in a big batch when the new velcro bin is empty.


Blue Flex Sanding Disks & Interface Pads

Photo: Blue Flex Sanding Disks & Interface Pads (sanding_bu_pads_blue_flex)

See my Blue Flex Sanding Disks blog entry for more information.


Mirka Autonet Sanding Disks & Interface Pads

Photo: Mirka Autonet Sanding Disks & Interface Pads (sanding_bu_pads_autonet)

See my Mirka Autonet Sandpaper blog entry for more information.


Sanding Drill

Photo: Sanding Drill (sanding_bu_pads_19)

I like to use a low profile angle drill for my sanding on the lathe. See the bottom of my Blue Flex Sanding Disks blog entry.


Sanding Cheat Sheet

Photo: Carl's Sanding Cheat Sheet

Check out my Sanding Cheat Sheet. It ties all of my sanding blog entries together. Wet Wood? Already Finished? Spindle Turning? Bowl or Hollow Form? Then use …