To sand the saw scratches out of the profile without spoiling its shape
and crisp edges, you need a sanding block that’s made to fit the profile.
An easy way to do this is with Bondo-type auto-body filler (Photo 8).
When you sand the profile, start with 80-grit sandpaper and move up to
220 grit. When the panel is fully sanded, it should easily slip into the
door frame without rattling around inside it.
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Make a sanding
block that’s the exact shape of your coved profile. Mix auto-body
filler and pack it into the cove, with a layer of wax paper over
the wood to prevent it from sticking. A piece of scrap creates a
dam to hold the filler in place.
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Add a handle
to the sanding block while the filler is wet. This makes it
a lot easier to hold the block when you’re sanding. When dry, the
filler creates a sanding block perfectly formed to the cove.
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Attach sandpaper
to the sanding block. Self-adhesive sheets are the easiest, but
you can also use self-adhesive discs, cut in half.
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Sand the
cove, starting with 80-grit sandpaper and moving up to 220 grit.
Every so often, check the fit of the panel, to be sure you’re not
making the tongue too thin.
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