I want to create the "Best Sanding Blocks Ever"

I finally was able to use mine. They are extremely comfortable, very ergonomic in the hand. The weight is nice on a horizontal plane, jury is still out on how it will fatigue the arms on vertical planes.

The two downsides were they load up the sandpaper a lot worse than my Durablocks. The Durablock tends to push the dust around but the hard backing on these smashes the dust right into the paper.

My Indasa paper sticks to the backing too and was a bit of a mess to clean up.

Once I get to stuff like hood, roof and bedsides the longer block will shine.
 
Lizer said:
The two downsides were they load up the sandpaper a lot worse than my Durablocks. The Durablock tends to push the dust around but the hard backing on these smashes the dust right into the paper.
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Could it be that the Black Diamond block is so flat that more of the sand paper is in contact with the surface, causing your problems. Maybe need to clean the paper more often.
 
chevman said:
Could it be that the Black Diamond block is so flat that more of the sand paper is in contact with the surface, causing your problems. Maybe need to clean the paper more often.
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That was also my thoughts. I've noticed when I use a wooden block that has been trued it does same thing.
 
chevman said:
Could it be that the Black Diamond block is so flat that more of the sand paper is in contact with the surface, causing your problems. Maybe need to clean the paper more often.
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Probably but the problem was the paper loaded up in almost no time at all. Like with just a few strokes.
 
Whenever I am blocking I wipe the block across my jeans every other stroke. Keeps the paper from clogging. Doesn't seem to wear out my jeans any quicker.
 
It’s been my experience that the cheaper papers tend to leave adhesive and load up worse than premium versions. Granted, I haven’t tried them all but it always seems the cheaper products are a tradeoff in more time and/or materials.
 
Here's a couple "hacks" I've picked up on from customers:
  • Use a brush to keep the paper clean. Works great! Picture of what I use below. Saw this on "My Friend Pete" video review and starting using it.
  • If the PSA paper you are using is leaving residue, put clear packing tape on the polycarbonate and then stick the paper to that. I've tried it and it works really good.
Yes, any block with acrylic/polycarbonate base is going to cut more material per sanding pass and subsequently load any sandpaper faster. With quality sandpaper, the dust can be brushed off and continue to cut well for a long time.
The reason acrylic/polycarbonate creates more dust per pass is because A) The block surface is flexing to the shape of the panel, resulting in higher surface area contact and larger area being sanded and B) the dramatically harder surface (vs. a Durablock) is pushing that paper harder against the substrate being sanded, for a given applied force.

Details for my fellow science geeks
Flexibility and hardness are two separate measures. Durablocks have both measures working against them.
They are not flexible, so they do not conform to a surface with any crown (nearly every panel)
They are relatively soft (Shore A scale = about 50.) So when you press them against that panel, the block acts like a shock absorber, compressing and allowing the paper to sink into the block. High spots and larger imperfections like filler edges or ridges are likewise partially absorbed into the foam block surface.
Polycarbonate does not yield at all and so all of the applied force is transmitted to the sandpaper and substrate. Imperfections yield to the sandpaper much better; more quickly and flatter.

Durablock hardness reading

Durablock durometer.jpg


Black Diamond harness reading (note the scale on the meter is 0-100 HA - basically maxed out the gauge)

BD durometer.jpg


Here is the brush I started using to clean dust off the sandpaper

brush.jpg


Packing tape I'm using on the base to eliminate residue

packing tape.JPG
 
I like that idea about the packing paper!

I use my air hose to blow the sandpaper off, but I would agree A brush would be more effective and less dusty. Or I just wipe it off with my hands.

Subsequently, I’ve had better luck with the sandpaper, not sticking. I just have to be careful on how I remove it.
 
Holy crap do these thing cut flat. I could cut finger on that filler edge. Only problem is they wear you out trying to make them flex into low spots when you are to lazy to mix more filler like I do with Durablocks :p

IMG_4904.jpeg
 
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