I want to create the "Best Sanding Blocks Ever"

Dean Jenkins said:
Curious, do the different diameter rods go in the same holes? Do they stay in with friction?
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Yes, they all go in the same holes. The smaller are a bit loose, but I imagine they would be used in a more crowned application where the bending action would better hold them in place.

edit* @Dean Jenkins Perhaps alternate/extra holes that fit would be a better option.. ??
 
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The holes in the angled ends have a clamping action as the end bends slightly for rod to pass through. At least that is how it looks on mine.
 
Dean Jenkins said:
I've been thinking about adding some "splines" to the Black Diamond product lineup.
Last year I bookmarked this thread started aby @orangejuiced86

Bodyfiller splines

I am interested in making a set of long splines for spreading filler. Had anyone made some of their own before? I have a few plastic companies close to me. I am just curious if you have made a set what did you make them out of? I'd like to make them as long at 30". I have looked online and I...
www.spiuserforum.com

Seems like what is available is sort of ridiculously priced. C'mon, they are HDPE sheets cut to a specific size and shape.
Same type of approach can be used to make tools for gaps as well.

Curious about everyone's thoughts on this.
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I bought a few sheets of HDPE and cut it to make my own spreaders. It was was cheaper than the pre-made kit being sold out there.

As for the spline idea there's a company out of Australia that makes a really nice kit that I've been tempted to pull the trigger on..
 
Dean’s blocks plus my trusted straight edge is a winning situation. 80 grit “rough” blocking

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@JimKueneman I wish I had the time to get my grandpa’s truck that straight but I’ve resigned to the reality that I am going to have to make some concessions. I work full time, I farm on the side, and I have a 3 year old. Somewhere in there I’m supposed to work on my cars. This truck needs to get out of my shop and hair by spring because I’m building a new shop next summer and that will be the only thing I’m working on. I blocked 3 coats of Featherfill but still can see a ripple or two.

How much body filler did it take to skim coat that? I might skim coat the hood because it’s kind of a hot mess when I “see” it with my flat hand.

Back to the blocks, I put about a one inch piece of heat shrink tube on the end of the rods just under the grip on the ends of the rods like suggested by Don. It looks professional like it is supposed to be like that and works really well.

These blocks do make me less of a hack. I’ve never been able to get stuff as straight as what I’m doing now.
 
Lizer said:
@JimKueneman I wish I had the time to get my grandpa’s truck that straight but I’ve resigned to the reality that I am going to have to make some concessions. I work full time, I farm on the side, and I have a 3 year old. Somewhere in there I’m supposed to work on my cars. This truck needs to get out of my shop and hair by spring because I’m building a new shop next summer and that will be the only thing I’m working on. I blocked 3 coats of Featherfill but still can see a ripple or two.

How much body filler did it take to skim coat that? I might skim coat the hood because it’s kind of a hot mess when I “see” it with my flat hand.

Back to the blocks, I put about a one inch piece of heat shrink tube on the end of the rods just under the grip on the ends of the rods like suggested by Don. It looks professional like it is supposed to be like that and works really well.

These blocks do make me less of a hack. I’ve never been able to get stuff as straight as what I’m doing now.
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That truck has taken a gallon per side.... They were never meant to be straight. I have never used more than a gallon on an entire car.... It has been time consuming to say the least.
 
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