Bevel handsanding tool V3, AKA The Holy Stick

thingiverse

Description ==================== This is a simple yet effective tool designed for handsanding knife bevels. It features a clamping system that holds the abrasive media for you, as well as swappable backer blocks for different types of bevels. Use it with strips of sandpaper or 1mm thick felt (for polishing compounds) up to 25mm wide. Contact faces are chamfered on one side and shouldered on the other, to make them easy to print and usable for bevels with plunge lines. Attached are models for a flat backer as well as backers with curvatures matching 100, 150, 200, 250, 300, 370 and 450mm diameter, though more backers may be added in the future. ###Besides printed parts, for assembly you'll need: 2x m5 45mm bolts 2x narrow m5 nuts 2x 3mm diameter 45mm long stainless pins 2x 10mm diameter ~1mm wire diameter 25mm long stainless pressure springs. **Above hardware kit, as well as fully printed kits ready for use, can be purchased from me. Contact via Instagram: @orionknifeworks.** Printing ==================== All parts can be printed with no supports. I suggest using following configuration for all parts: 0.4mm nozzle 0.2mm layer height PETG filament No brim 40% infill ### Considerations for printing stick body The stick body should be oriented with the bottom flat surface towards the build plate. It fits diagonally on and E3 bed. This design requires additional infill on the middle (hollow) part. The best way to achieve that is adding two cuboid models to your slicer, positioning them so that they just overlap with the side walls, and changing their mesh type to modify the wall thickness setting to 7mm on overlaps, as shown in the pictures. **Failing to do this step may result in your stick breaking during use**. ### Considerations for printing clamps Clamps should be positioned with the hinge hole vertical. After printing, ensure that the hole is a sliding fit over the hinge pins. If necessary, that hole can be reamed to achieve that fit - I suggest using a 3.2mm drill bit. Also, ensure that the area where the clamps make contact with sandpaper is straight - any inconsistencies need to be flattened before installing, otherwise the clamping action will be uneven and the sandpaper will slip during use. ### Considerations for printing backers Backers should be positioned so that the holes are vertical and the side label is facing upwards. The holes should be a tight fit on M5 bolts. Assembly ==================== ### Hole reaming The holes in the stick body may need to be reamed for good fit. For that, you'll need a 5mm drill bit for the bolt holes and a 3mm drill bit for the hinge pin holes. This should provide a tight fit for the hinge pins. ### Installing the clamps Installing a clamp is as easy as positioning a clamp inside the stick, lining up the hinge hole and pressing in the hinge pin. To push the pin in, you may need to use a small hammer. The overall width of that part of the stick is 44mm, so the pin should just slightly protrude on both sides. Once the hinges are in place, you can insert the pressure springs - they should just snap in place when you slide them in. Congratulations, you now have a functional Holy Stick!