Friday, September 2, 2022

Wood Files with Handle

Looking at my metal files I thought why not make the same but for wood. Wood files with  a wood handle, they can be easily exchanged for the different grits of  any paddle. Easy to make and store and they work excellent!  

 To make the paddles I used 2x4's they are inexpensive and will work fine.  Sandpaper comes in sheets 9"x 11" . The length of the wood strips are 13 inches. They are 1.5 inches wide and 1/2" thick.                                               

To make the handle I traced a metal file handle onto a block and cut it out on the bandsaw. Always cut outside the lines so you can refine later.

Careful shaping was done on the bandsaw. Drawing lines of centers helps a lot. Filing the edges round  and sanding will give you a nice smooth handle.  


The handle was cut on the table saw with a sled,  this will ensure that everything keeps square. If you don't have a sled mark each side and carefully cut with a handsaw.

The handle was drilled using a 1/2" bit. The depth is 2 1/2 ". Make sure drilling is square or the paddles will sit crooked. You can also drill the blank before shaping which is probably easier. 

The paddle is now cut on the bandsaw, the piece extruding  is 1/2" by 1/2 inch and 2/1/2" long. The edges can be taken off using a metal file or sander. As you take away wood make sure to check regularly to make sure you get a snug fit. 

Different grits of sandpaper are now glued onto the wood. I used 60, 120, and 220. Wood glue was used for the sandpaper. After they were dried a utility knife was used to trim them. 

The sandpaper file can now be pushed into the handle. It is friction fit and should be firm, all the ones I made were a solid fit.
After testing it out it worked so well wonder why it took me so long to come up with this idea.

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