Sanding belts can wear down fairly quickly depending on your project. Building supply stores offer sandpaper for belt sanders in roll form, rather than single sanding belts. These sandpaper rolls can be cut and sized to fit your belt sander. Purchasing sandpaper for your belt sander in roll form and gluing the sanding belt using a building adhesive to ensure a tight bond is a cost-efficient method of replenishing your sandpaper.
Choose a grade of sanding belt paper according to the project at hand. A rougher grade sandpaper is needed for tougher projects.
Pull some sanding paper from the roll and wrap it around the belt sander pulleys. Overlap the paper by 1/2 inch. This will be where your glue bonds the paper together. Use a marker to place a mark 1/2 inch past where the paper meets. Remove the paper from the belt sander.
Turn over the sanding paper and use a protractor to measure a 32.5 degree angle from the mark previously made. Draw a line to the other edge of the paper following the 32.5 degree angle. Use a utility knife to cut the sanding paper from the roll. Cut along the line measured at 32.5 degrees. Repeat this step to cut the other end of the sanding at the same angle.
Use a ruler to measure 1/2 inch away from the edge of the sanding paper. Mark the measurement using a marker to draw a line across the paper. Use a rough stone or a filing tool to remove the sand from the rough edge of the sandpaper. Rub the stone or file along the 1/2 inch mark until the sand has been removed from the 1/2 inch area. Repeat this step on the other end of the sandpaper. This will create a flat smooth surface to bond the paper together.
Use a building adhesive to glue the sanding paper together in the form of a belt. Wrap the belt around a 2-by-4 with the rough side facing out and the glue areas on top of the wood. Apply building adhesive to both ends of the sanding paper using a paintbrush. Align the angles and touch the ends together above the 2-by-4. Place another piece of wood on top of the 2-by-4, pinching the sanding belt in between the two pieces of wood. This will ensure the the paper is flat and bonded well to prevent a loose wobbly belt.
Use two hand clamps to clamp the wood together and pinch the sanding belt paper. Allow the adhesive to dry overnight. Remove the clamps from the wood.
It is useful to make more than one belt at a time to give you extra sanding belts on hand.
The belt angle should run toward you when the sanding belt is installed and in use.