One of the biggest differences between a project that looks homemade and one that looks professionally crafted often comes down to sanding. Proper sanding removes saw marks, smooths rough edges, prepares wood for finishing, and helps bring out the beauty of the grain. Understanding sandpaper grits and the different sanding tools available can save time and greatly improve your results. What Do Sandpaper Grit Numbers Mean? The grit number refers to the size of the abrasive particles on the sandpaper. Lower numbers are more aggressive and remove material quickly, while higher numbers create a smoother finish.
Coarse Grits (40-80)
These grits are used for heavy material removal and shaping. 40 grit: Very aggressive, removes material quickly. 60 grit: Good for flattening rough lumber. 80 grit: Often used to remove deep saw marks and prepare rough surfaces. Most scroll saw projects rarely need anything coarser than 80 grit unless you're working with reclaimed or rough-cut wood.
"My local Dollar Tree sells packs of sand paper for $1.25 a pack."
Medium Grits (100-150)
These are the workhorse grits for most woodworking projects. 100 grit: Removes scratches left by coarse grits. 120 grit: A common starting point for many projects. 150 grit: Begins smoothing the surface for finishing. Many scroll sawyers find that 120 and 150 grit handle the majority of their sanding needs.
Fine Grits (180-220)
These grits prepare wood for stain or clear finishes. 180 grit: Excellent final sanding grit for many projects. 220 grit: Produces a smooth surface ready for finishing. For most scroll saw projects, stopping at 220 grit is more than sufficient.
Extra Fine Grits (320 and Higher)
Used between finish coats or for extremely smooth surfaces. 320 grit: Smooths finish coats. 400 grit and above: Polishing and specialty finishing work.
Sandpaper Types
Not all sandpaper is created equal. Different backing materials and designs work better for specific applications. Traditional Sandpaper Sheets These are the classic sheets found in most workshops. Advantages: Inexpensive Easy to cut into custom sizes Great for hand sanding Best Uses: Delicate fretwork Small scroll saw projects Areas power sanders can't reach
Sanding Sponges
Sanding sponges contain abrasive material bonded to a flexible foam block. Advantages: Flexible Conforms to curves Easy to hold Best Uses: Rounded edges Curved scroll saw pieces Decorative profiles Many scroll sawyers keep several sanding sponges nearby because they can reach shapes that regular sandpaper struggles with.
Foam Sanding Pads
These combine flexibility with replaceable abrasive surfaces. Advantages: Comfortable grip Consistent pressure Good control Best Uses: Intricate projects Fine finishing work
Abrasive Mesh Sanding
Mesh abrasives feature an open net-like design. Advantages: Resists clogging Lasts longer Excellent dust extraction Best Uses: Power sanding Resinous woods Large projects
Common Sanding Tools
Hand Sanding The oldest method remains one of the most useful for scroll saw work. Advantages: Maximum control Less risk of damaging delicate pieces Excellent for inside cuts Disadvantages: Slower More physical effort For intricate fretwork, hand sanding is often the safest option.
Palm Sanders
Palm sanders use a small square or rectangular pad that vibrates rapidly. Advantages: Easy to control Lightweight Affordable Best Uses: Small plaques Signs Flat surfaces Disadvantages: Slower than orbital sanders Not ideal for large projects
Random Orbital Sanders
These are among the most popular woodworking sanders available. Advantages: Fast material removal Leaves fewer visible sanding marks Excellent finish quality Best Uses: Flat project backs Plaques Cutting boards Large scroll saw projects Many woodworkers consider a random orbital sander the best all-around sanding tool for the shop.
Belt Sanders
A belt sander uses a continuous abrasive belt moving at high speed. Advantages: Extremely fast material removal Great for shaping Best Uses: Rough shaping Removing large amounts of material Flattening stock Disadvantages: Easy to remove too much material Usually too aggressive for finished scroll saw work Belt sanders are generally used before cutting the project rather than after.
Oscillating Spindle Sanders
These use rotating sanding drums that move up and down. Advantages: Excellent for curves Smooths inside cuts Consistent results Best Uses: Scroll saw patterns with curves Interior cutouts Decorative edges For many scroll saw enthusiasts, a spindle sander becomes one of the most-used tools in the shop.
Detail Sanders
These feature small triangular pads designed for tight spaces. Advantages: Reaches corners Good for detailed work Easy to control Best Uses: Intricate fretwork Tight inside corners Small decorative projects
Recommended Sanding Progression
For most scroll saw projects: Start with 120 grit. Move to 150 grit. Finish with 220 grit. Apply finish. If the wood has significant saw marks: Start with 80 grit. Move to 120 grit. Continue with 150 grit. Finish with 220 grit. Avoid skipping grits whenever possible. Each grit removes the scratches left by the previous grit, resulting in a smoother final finish.
Final Thoughts
Good sanding is often overlooked because it isn't as exciting as cutting a pattern or applying a finish. However, sanding is what transforms a rough project into a piece you're proud to display. Whether you prefer simple hand sanding, sanding sponges, palm sanders, or a random orbital sander, choosing the right grit and tool for the job will improve every project that comes off your scroll saw. The next time you're tempted to rush through sanding, remember: finishes don't hide scratches—they highlight them.