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Jewelry Tool Modification How to Make an End Sanding Bur

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.

Tool Making End Sander Header

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)

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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.

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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

6 thoughts on “Jewelry Tool Modification How to Make an End Sanding Bur”

  1. Michelle Sandler

    If I knew how I would send you a photo of me rooting in the garbage pail for the brush mandrel that I just tossed out yesterday.
    This is a great one thanks tons for all these amazing tool tricks.

  3. MHann

    Was sitting with my morning coffee trying to figure out how to clean up the inside of a bezel back I’m working on to a higher standard when up pops your end-sanding bur idea. Thanks! I’m really enjoying your blog.
    One good tool deserves another. I wanted to share my best find of late.
    Always scrounging for just the right size cylindrical mandrel, at Harbor Freight I found a 28 Piece Transfer Punch Set for about 10 bucks. It includes 3/32″ all the way up to 1/2″ (by 64ths!) carbon steel punches plus a 17/32″. 28 useful sizes. Each mandrel/transfer-punch is about 5″ long. Plenty good for jump rings etc. This thing has saved me so much scrounging. Cheap and functional.
    Thanks again.
    M

  5. Grace

    Doug, I’m tempted to cut down some mandrels with brushes still on them this tip is SOOO good. And, of course, I just found out that the micro polishing papers have adhesive backings on them, so a flat mandrel would be the perfect application. Genius…that’s what this is!!

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