Sanding Saw

For those of us who collect homemade sanding blocks or need to sand around corners and curves, may I present to you this homemade bow sander.

This bow sander is great for tight, curved places and works from both top and bottom.

Maybe your great grandchildren will look at yours someday and ask, “What was that thing for anyway?

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I would also apologise for my English as a non-native English speaker some terms are very difficult for me. Forward, Instructable!!

MATERIALS

• Sycamore wood
• Oak wood
• Beech wood (wooden rod 380x25mm 1"x15")
• Leather
• Linseed Oil
• Cloth Sanding paper

TOOLS

• Pencil and ruler
• Japanese Saw
• Clamp
• Mini Try Square
• Rasping Riffler File
• Saw rasps
• Flat Wood Bits
• Woodthreading Kit, 1" x 6 TPI
• Block plane STANLEY
• Plane No. 5 STANLEY
• Engineers Square
• Gauge Veritas
• Chisels
• Scrapers
• Dowel marker
• Spokeshave Stanley
• Gouge cut 3 straight (Pfeil)
• Rotary Cutter
• Hammer

Draw the contour of the handle saw on a piece of wood. I used Sycamore wood but you an use other type.

I cut the straight zones with a Japanese Saw and the curved zones with a chisel, a file cut and and finally with a scraper.

Since in this project I did not want to use glue, I though to join the pieces A and B with threads. For this I used a woodthreading in both sides of a wooden rod of beech wood (25x380mm or 1"x15")

Mark the centre of the pieces (A and B) and drill it with a flat wood bit of 22mm in the A piece and 23mm in the B piece.

Cut the wooden rod at a length of 15" or 380mm and before making the threads we cover it in linseed oil and wrap overnight with film in order to absorb the oil and make easier the threads. Apply also the linseed oil in the hole of the piece A.

Then we make the threads with the Woodthreading:

- 1 in piece A as per photograph.

- 2 in both sides of the wooden rod.

For a smoother touch of our handle saw round the vertices. I use a spokeshave, a block plane, a gouge cut 3 straight and finally with a grid 280 sandpaper.

For the inner part I use a Rasping Riffler File .

For the nuts I used oak wood.

Use a compas to draw the nuts on the wood making a circle and marking a hexagon with it. Drill the centre with a bit of 22mm and make the thread. Then cut the sides of the hexagon with a saw.

Since we need 2 nuts, we divide the piece into 2 equal nuts with the help of a gauge and a saw.

Once all the pieces created, we have to locate the sanding belt.

I leave a drawing with the place where I made the holes but if you have changed the sizes you will have to adapt to yours.

So that the paper sanding does not break

For avoid breaks in the paper sanding while sanding, I created a leather belt. I sewed 2 little rods at both ends but if you prefer you can use contact glue or similar.

Finally, I apply linseed oil to all pieces and assemble what I have called "SAW SANDIG"