Continuing our efforts from the previous blog, we have a fan-like drawing stuck on a piece of 1/4" ply to use as our template. Now we need to cut it out so it can be used as a template to cut some hook material for our power sanding block and, ultimately, the loop backed disks.

I started by drilling 1/8" holes at the point of each 'dart' that needs to be cut. This just makes it easier and cleaner when cutting up to the point. I cut the circle out on the band saw and then cut all the darts to finish the cutting template.

Next, I clamped the template to my bench with my PSA backed hook material trapped in between. Again, I cut around the circle, then notched out the darts. Use a fresh blade in whatever knife you are using, and cut firmly to obtain clean cuts. The clamped parts will need to be rotated, to get under the clamp, so be careful not to mis-align the template and material as you do.

With the hook part cut, it can be applied to the hemisphere. Getting the center of the hook properly located on the apex of the dome is important, so take the time to get it right. Start sticking the hook down in the center and work opposite 'legs' down from center out. Be careful to press them flat, but do not try to stretch the hook tight by pulling, the tension caused will tend to pull the legs loose over time. (Don't ask how I know this!)

PSA adhesives are generally formulated to set in 24 hours, so I taped all the legs tight on the block and left it to set. Like most things in woodworking, patienIn the meantime, please feel free to comment here on the blog, on our Facebook page, or via Twitter. -2Sand.comce is key. So while you are waiting for the glue to set and for the next blog, please feel free to comment here on the blog, on our Facebook page, or via Twitter. -2Sand.com