Cool & easy to make jigsaw sanding blade

Cool & easy to make jigsaw sanding blade

Build a workshop | Woodworking jigs
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Is this recognizable: you want to sand an almost completed project and you notice small openings that you can barely reach.

You will need to cut a piece of sandpaper to size to smooth out that tiny opening but after a long struggle, you do not get the desired result.

This is a thing of the past with this jigsaw sanding blade.

Read on to find out how easy it can be.

I, too, had had this problem described above several times before.

That is why I was looking for a solution and made this jigsaw sanding blade.

It is an easy to make DIY woodworking tool that allows you to quickly replace the sandpaper with the built-in clamping system.

In this blog, I will explain step by step how to build this jigsaw hack yourself and I make a list with all the necessities for this DIY woodworking tool.

Watch the video here

Before we start building​

To prepare you for building this project, I have made a few handy lists.

In addition to a few personal protective equipment that I use*, I also list the materials as well as the (power) tools you will need to build this jig.

* Safety is always your own responsibility!

Safety first!

Materials I used for this jigsaw hack

(power)Tools I used for this sanding blade jig

How to make the jigsaw sanding blade step by step​

Now that we have gone through the list of what we all need to make this jigsaw hack, I will explain step by step how to make this jigsaw sanding blade.

Let’s go!

Step 1 | Base​

For the base of this jigsaw sanding blade, I used a piece of pinewood from my scrapwood storage cart.

The piece I used has dimensions of 6cm (2.36″) long, 2cm (0.78″) wide and 2cm (0.78″) thick. 

Keep in mind that the dimensions may be different for your jigsaw.

To cut the block safely I used my crosscut sled.

Cool & easy to make jigsaw sanding blade

Tip:
Be sure to watch my video how I made my crosscut sled: The perfect crosscut sled? Accurate | removable zero clearance insert

I hope to be able to make some free plans of the crosscut sled in a few weeks and make a blog about it, so keep an eye on my website or subscribe to the newsletter to be the first to know when I upload a new blog.

Step 2 | Groove​

To fit the jigsaw blade into the piece of wood, I made a slot with the handsaw.

This slot is slightly less deep than the width of the blade.

By tapping the jigsaw blade into the block with a hammer, the teeth of the saw blade will lock into the wood.

Cool & easy to make jigsaw sanding blade

Step 3 | Secure the sawblade​

I secured the jigsaw blade in the wood with screws.

To do this I connected the saw blade and the wood with painter’s tape so that they could no longer move relative to each other.

Then I drilled a hole through the wood and the saw blade with the drill press and a drill bit just smaller than the diameter of the screw.

Cool & easy to make jigsaw sanding blade

The second step in securing the saw blade was that I made the drilling hole slightly larger before installing the screws with a countersink.

This allows the screws to be placed flush with the surface of the wood.

Cool & easy to make jigsaw sanding blade

Step 4 | Round the nose​

When working with this tool, the jigsaw sanding blade will make quick movements up and down. 

To avoid kickback when the bottom of this jig lands directly on the workpiece, I rounded the nose.

From the center of the wooden block, I made a circle so I could see which surplus material I could take away with my DIY drum sander.

Cool & easy to make jigsaw sanding blade

Step 5 | Clamping system​

I think the big plus of my Jigsaw sanding blade is the handy clamping system.

This makes it possible to replace the sandpaper in a very quick way.

No fumbling with glues or double-sided tape, just loosen two screws and the sandpaper can be changed.

Cool & easy to make jigsaw sanding blade

I made the clamp on the top of the jigsaw blade from a surplus of T-track rail.

With the hacksaw and my Dremel, I was able to cut out a piece with the same width of the jigsaw sander blade. 

Because the piece of aluminum has an angular shape, it fits perfectly on the piece of wood and the sandpaper will be clamped in 2 directions.

Using painter’s tape, I placed the piece of aluminum in the correct position on the jigsaw sanding blade so that I could make a hole with the drill press.

Cool & easy to make jigsaw sanding blade

In that hole will fit a screw to tighten the clamping system.

Cool & easy to make jigsaw sanding blade

A second clamp will be attached to the back of the jigsaw sanding blade.

To do this, I drilled a hole about 2cm (0.78 “) from the end of the jigsaw sanding blade with the drill press.

Cool & easy to make jigsaw sanding blade

To clamp the sandpaper to the sanding blade I placed a screw and washer in the drilled hole.

Cool & easy to make jigsaw sanding blade

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How to use the jigsaw sanding blade​

This Jig is very easy to operate.

Start by loosening the screws for the clamping system. Then slide a strip of 2cm by 14cm (0.78″ by 5.5″)  sandpaper over the jigsaw sanding blade.

First, clamp the corner profile in aluminum. Screw it tight so that it cannot come loose from the quick movements the jigsaw makes.

Cool & easy to make jigsaw sanding blade

Stretch the sandpaper over the sanding blade and place the second clamp. 

Determine where the drill hole is and pierce the screw with the washer through the sandpaper.

Now tighten it firmly so that the washer holds the sandpaper in place.

Cool & easy to make jigsaw sanding blade

Place the jigsaw sanding blade on the jigsaw just like you do when you place a saw blade.

Cool & easy to make jigsaw sanding blade

You are now ready to sand small openings with ease.

Don’t know which sandpaper to use?

The range of different types of sandpaper is so large that you probably no longer know which sandpaper is for which job and you possibly use the wrong sandpaper a lot.

That is why I wrote a blog to give you insights about the choice of the right sandpaper.

Check out the blog “the perfect sandpaper grit guide for woodworking” and download the handy FREE guide.

Cool & easy to make jigsaw sanding blade

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2 Comments

  1. I love your ingenuity. I just made a “Mexican Train Station” for dominoes and this would have been the perfect sanding tool for the individual docking stations. Will be making a set of these for different grits.

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