Simple DIY Flap Sander

Avatar Katelyn | June 26, 2017 12 Views 0 Likes 0 Ratings

We’ve got a quick tip today – how to make a simple DIY flap sander. There are a lot of elaborate DIY flap sanders out there, but this is one you can make in a pinch. It’s great for getting into hard to reach spaces that are hard to get with a typical flap sander. Plus it’s super flexible: you can make it long and skinny, you can make the sandpaper itself longer or shorter, and you can swap out the grit whenever you need to.

Tools and materials needed:

Simple DIY Flap Sander

Step 1: Clamp and Cut

First clamp down some ⅜” aluminum bar stock and cut off the length you need with a jigsaw using a metal blade.

Simple DIY Flap Sander Simple DIY Flap SanderWe cut off a length that was about 4”, but you could go longer if you needed to.

Simple DIY Flap Sander

Step 2: Turn Into Split Mandrel

We’ll turn this piece of aluminum into a split mandrel to hold our sand paper. We placed it on our drill press V block to keep it centered (which we clamped into place), and cut a slit into it on our band saw.

Simple DIY Flap SanderSimple DIY Flap Sander

Step 3: Insert Into Drill

Then pop the split mandrel into your drill and place a folded piece of sandpaper in the slit.

Simple DIY Flap SanderSimple DIY Flap SanderTighten the split end around the sandpaper with some pliers.

Simple DIY Flap Sander

Step 4: Enjoy!

This is great for getting hard to reach spaces that a store-bought flap sander can’t get to, and it’s really so easy to make.

Simple DIY Flap Sander Simple DIY Flap SanderSimple DIY Flap Sander

Hope y’all found this helpful, let us know if you have any questions! Simple DIY Flap Sander

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