How To Make Detail Sanding Pens for Fine Woodworking

While Proxxon carries great electric detail sanders (Pen Sander PS13 and Belt Sander BS/E), sometimes a woodworker still needs to use manual sanding. That's why I made these detail sanding pens for fine woodworking. They are wonderful for those tiny, hard-to-access areas, like in fretwork. The original pattern for these detail sanding pens can be found on the Scrollsaw Workshop blog.

Supplies and Equipment for Making the Detail Sanding Pens

• Scrap wood pieces 1" x 6" (or longer)
• Thumb tacks
• Fine grit sandpaper
• Pattern for sanding pens (search for "detail sanding pen")
• Proxxon Band Saw MBS/E
• Proxxon Scroll Saw DSH/E
• Proxxon Professional Rotary Tool IBS/E and MICROMOT Drill Stand MB

Instructions for Making the Detail Sanding Pens

1. Print the patterns and adhere to the wood. Cover the surface of the wood with painter's tape. Next, spray the back of the pattern with spray adhesive, and put that on top of the painter's tape. The spray adhesive holds the pattern in place, and the painter's tape makes for easy removal.
   
2. Cut the outline shapes of both the large and small sanding pen and kerfs on the large sanding pen on the band saw.
   
3. Cut the notch on the small sanding pen on the scroll saw. (See note below.)
   
4. Using the professional rotary tool and drill stand, drill a 1/16" hole in the large sanding pen for the tack that will secure the sandpaper in place.
   
5. Realign the rotary tool and add a sanding disc to sand the pieces.
   
6. Insert the tack into the drilled hole. If it extends beyond the pen piece, trim with wire cutters.
   
7. Cut lengths on fine grit sandpaper to wrap around the sanding pens, and secure with the tacks.
   
8. Enjoy your completed detail sanding pens!!
   

Note: I was not pleased with the notch arrangement for securing the sandpaper on the small sanding pen, so I modified the pattern as show below. I eliminated the notch and used a tack to secure the sandpaper.

Used along with the Proxxon detail sanders, these will do the job for fine woodworking.

Carole