How to Sand Designs Into Metal

You don't need an elaborate metalworking shop to sand designs into metal.

Metal is a wonderful fine-art and crafting material. It is strong and durable, but also versatile and easy to work with. With just a few tools available at any hardware store, you can sand a design into metal in not much more time than it would take to sand a design into wood. With the right preparation, you can safely augment an existing metalworking project, or make a stand-alone drawing on metal.

Things You'll Need

• Handheld rotary cutting/sanding tool
• Metal sanding accessory kit
• Clamps
• Pencil
• Eye protection

Instructions

1. Clamp the metal piece to be sanded onto a worktable. Make sure the working area is free of debris that could catch on the cord of the handheld rotary tool.

2. Sketch the design to be sanded onto the metal with your pencil. Begin with a simple design, using just a few shapes. As you become familiar with the tool, you will be able to execute more complicated designs.

3. Select a metal sanding accessory with a relatively small cutting surface---you can use larger accessories to shade larger areas, but a smaller component will work better for sanding lines.

4. Open the chuck on the rotary tool and insert the accessory. Tighten the chuck firmly. Put on your eye protection, and make sure the tool's cord is clear, allowing you a free range of movement, with no possibility of the cord entering your working area.

5. Begin sanding with a light touch, keeping the rotary tool moving to avoid scorching the bit or the metal. You can always go back later and make deeper cuts as you become accustomed to the tool.

6. If metal particles begin to accumulate on your working surface, turn off the rotary tool and sweep the metal clear.

Tips & Warnings

• Practice with a piece of scrap metal, experimenting with the different marks you can make with your rotary tool. Try holding the tool at different angles to achieve different effects.

• Always remain aware of the location of your fingers in relation to the tip of any cutting or sanding tool.

References

• Techniques and Tips for Cutting Metal