I want to create the "Best Sanding Blocks Ever"

So I’ve finally found an issue with the blocks :( The rods will not stay in my long block, they just slide out easily. Even just from sanding a light cross hatch they were sliding out. You might need to make the holes smaller Dean.
 
Lizer said:
So I’ve finally found an issue with the blocks :( The rods will not stay in my long block, they just slide out easily. Even just from sanding a light cross hatch they were sliding out. You might need to make the holes smaller Dean.
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If I make them smaller, the rods won't fit when they are new.
As a few have mentioned, there are some hacks like tape or shrink tubing.
I'm looking into making the rubber caps longer and tapered so they will wedge into the block and hold the rods even if the rubber handle relaxes and the holes open up a bit.
 
Can't you soften the square end of the rod so its not gouging the rubber, which makes the hole bigger? Wouldn't have to be to a point.
 
Dean Jenkins said:
If I make them smaller, the rods won't fit when they are new.
As a few have mentioned, there are some hacks like tape or shrink tubing.
I'm looking into making the rubber caps longer and tapered so they will wedge into the block and hold the rods even if the rubber handle relaxes and the holes open up a bit.
Click to expand...

Don't make the holes smaller for obvious reasons.

I commend you for addressing the issue but, if it's going to cost you more to fabricate the rubber ends with a taper, value engineering leans towards supplying small pieces of shrink tubing with the blocks so the end user has what's needed in the event they have an issue, or just supply instructions on how to address the issue if it occurs. I had that issue and used tape to correct it. I like the shrink tubing idea best for a cleaner look.
 
Hey Dean. I finally caved and put in an order last night. I hadn't been following this thread but since I had a holiday weekend I took some time to read through the 26 pages. Just wow. You've been busy. Looking forward to getting my sanding blocks. I'll be using them on my own projects now that I consider myself semi retired.
 
chevman said:
Can't you soften the square end of the rod so its not gouging the rubber, which makes the hole bigger? Wouldn't have to be to a point.
Click to expand...

The rod ends are circular. They could be rounded over but, that would be another added cost. Personally I think the rods slipping out is part of the nature of the beast. It's going to happen if you remove and insert the rods multiple times, which we all do, to obtain the desired stiffness of the block for the panel we are working on.

This really is a none issue to me.
 
Skim coat in the morning and time for some 24” blocking reviews.

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Jimmy likes this long block for the A100.... Factory original ripples highlighted with the block and 400 grit... Skimmed the lower section and blocked it out... This long block takes a man... Jimmy is not a man.. but Jimmy will be a man when this is over... Jimmy blocks for a few passes front to rear then he sits down and takes a break... he then makes a few more passes... and sits and takes a break.. Jimmy is not going to make a video until he can make it look like he can block all day...

It is bloody straight and with the hard backing it make the paper cut FAST.. it is worth the effort to say the least.

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MJM said:
The rod ends are circular. They could be rounded over but, that would be another added cost.
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The rods are currently machined after being cut. See close up picture. I didn't want a sharp edge at the tip to hang up or damage the hole in the rubber handle.

I think the consensus is the same as yours, not a big issue, but if I can make a cost effective change to help, I will.

Rods machining close up.jpg
 
The tooling/molds for the 24-inch blocks is done. Below is a short YouTube link to the molds being CNC machined.
The factory will run a handful of samples through the new tools and ship them to me for approval.
I should have them in hand in 1-2 weeks. If all looks good, I will approve production of the first batch of 500 of the 24-inch blocks.

I'll offer a significant "Pre-sale" discount on the first 100, just like I did on the initial block set. If you are interested in that, stay tuned and get your order in when I post it.

 
It’s interesting that the rods in my AFS block stay put. They take a bit of effort to remove.

Not complaining or criticizing, just sharing a data point.

Don
 
dhutton01 said:
It’s interesting that the rods in my AFS block stay put. They take a bit of effort to remove.

Not complaining or criticizing, just sharing a data point.

Don
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Interesting. I've heard quite a few reports that they started falling out as well, since they used steel clips in the body of the handle, which were subject to some wear over time.

I'm thinking that the tapered caps might be a great solution, but hope to hear some thoughts on that.
 
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