A few weeks back I began a rather involved project that has legs that have stop-flutes. After posting about my shop-made scratch stocks, I hoped to do a majority of the work using a router with a fluting router bit only to clean and straighten up the flute portion with the scratch stock. The bead area had to be fully scratch-produced.
As you can imagine working with a router bit and a couple of scratch stocks, the surface of my stop-flutes needed to tweaked to be smooth. (No, my first thought wasn’t a mounted flap-wheel chucked into a drill.) I grabbed a piece of scrap and made a concave edge using the tip of a small router bit (you can see the results in the above photo).
For the flutes – the areas that really needed to be cleaned – I wrapped a sanding disc around an appropriately sized dowel, which happened to be a short length of pencil. There wasn’t much to grip as I sanded, so the pencil kept sliding back and forth. As my frustration grew, I thought about sticky-back sandpaper, but there is none in my shop. Everything is setup for hook and loop.
My next thought, which should have been my first due to the success of the bead-sanding tool, was to make a convex edge on a scrap around which I could wrap and hold the sanding disc. The convex sanding tool worked as good as did the concave design. Sometimes simple is the best way. These are another example of inexpensive, but useful tools.