How to Make an End Sanding Bur

Y’all know I like to make and modify tools whenever possible, so here is a quick one for you.Have you ever been working on a piece of jewelry, and needed a tool that just wasn’t in your tool arsenal? This is the story of just about every tool I have made or modified. Allow me to share a tool that I make that is worth its weight in candy bars, or something good like that.

If you have ever used an End Brush, or used one up, do not throw them away when you are done with them. These can be modified into great end sanding tools. First, I mount the used up end brush into my Foredom and turn it slowly while I saw into it with a Saw Frame. I use a 3/0 Saw Blade to do this. I cut almost all the way through, then I just snap it off with my fingers. Now I have a flat ended mandrel.

Tool Making End Sander (1) Tool Making End Sander (2)

Tool Making End Sander (3) Tool Making End Sander (4)

After I cut the end off, I take a small ball bur and add a little “texture” to the end of the mandrel. I used a 0.8mm Ball Bur in this instance. I cut a small piece of Sandpaper, a little larger than the end of the mandrel. I add a drop of Super Glue to the mandrel and apply the sandpaper to the mandrel, grit facing out. The texture that was added is to hold onto the glue better.

Tool Making End Sander (5) Tool Making End Sander (6)

After the sandpaper is glued to the mandrel, and the glue has dried, I trim the excess off with a pair of Semi-Flush Side Cutters, then file the edge flush. I use an old #4 Flat Hand File to do this.

Tool Making End Sander (7)

I have a number of these end sanders around with different grits of sandpaper, from 320 to 600. They get inside of areas and sand flat areas, they work quick, and it the sandpaper loses it’s cut, just take the old paper off (I use a Surgical Blade) and add another piece of sandpaper.

Tool Making End Sander (8) Tool Making End Sander (9)

Again, this is a great tool to have around and definitely worth its weight in candy.

Now, enjoy this little gem and go out and see if you can make a kid smile today!

Doug

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