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 Inside Curves

 I am not sure what you guys use/used to sand inside curves. The area where your lift duct and plenum merge and your lift duct opening are two examples.

UH suggests a foam file, but I couldn`t find one or anyone that ever heard of one, a regular file is way too slow. Normal sanders are flat and dig in, but in general power tools blow that styrodust everywhere.

So, decided to make one. I use a two foot piece of really skinny wall three inch aluminium pipe, because it is light, but plastic pipe would be fine too. I bought several different course grits of 6" x 48" belt sander belts. Cut in half makes two 6" x 24"  `wraps' for my three inch pipe, it covers most of the pipe. I just tape them on down the sides and avoid sanding on the tape. It works well for these inside curves. Please add you ideas, sanding could be made a lot easier for all of us. Mike

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Northern Hover   |2010-01-29 21:31:27 mike I have some wood rasps and grater style rasps. I won't need them right away b/c I need to pull my subaru apart before I get into making a mess with foam. Drop me a PM, I'm not too far away. Cheers Albert

gone7  - Sanding stuff   |2010-01-27 21:50:48 On my Sevtec projects I've used a common wood rasp and it seemed to work really good. Although on these we typically are building with "Last-a-foam" and I would guess it would react differently than the more common foams. I haven't worked too much with the common foams. I'd read once where someone suggested using the "Surform" tools on foam. I haven't tried any of those yet but they do come in a variety of shapes and sizes. Guy

hoverwest  - curves   |2010-01-26 16:54:26 I have done something similar with a wood 1" wood dowel, and for a real small radius I use a coarse rattail file. The file works well for inside and outside radius's. I know what you mean about that area on the lift duct, a large tube as you describe would work very well. Jake W.

edaho   |2010-01-26 06:48:54 Hi Mike, What I did was shape a piece of two inch thick Styrofoam, about four inches long, to a gentle curve and taped sandpaper to it on the flat top.

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