Replies

1. 
   john_c2 | Dec 07, 2020 01:26pm | #1

   Try any kind of file you have. You can often buy files for cheap money that have been worn out on metal, but still work ok on wood. Metal files on wood are slow, and clog pretty frequently. But they leave a somewhat fine surface.

   Rasps come in a huge range of "grits," and remove wood faster than files. A course rasp can leave a torn up surface, while a fine rasp can leave a pretty smooth surface, but cut much slower.

   The only thing that will leave a surface as smooth as 400 grit sandpaper is 400 grit sandpaper. You'll still have to do final smoothing after rasp and file work, but they will get you there faster and cheaper than just the sandpaper will.

2. 
   rob_ss | Dec 07, 2020 03:24pm | #2

   probably what you need is either 60 grit sandpaper glued to MDF (the stiff backing not only gives better control but prevents cracking so the paper lasts longer by far) or some carbide paper.
   This video shows the product in use. It's not for the faint of wallet...
   https://www.youtube.com/watch?v=6Wnkh2MNu0E

3. 
   ysu65 | Dec 07, 2020 07:03pm | #3

   I got the hand stitched rasps from stewmac.com when I was doing the Maloof rocking chair. They sell tools for making musical instruments like guitars. I got both the rough and fine, then got the small versions as well. There are French ones that are very good and they come in a variety of grits. The ones I bought don't wear out like sand paper. The rasps are my go to tools for shaping things, sand paper for final smoothing. They work way better than files IMHO.

1. 
   john_c2 | Dec 07, 2020 07:32pm | #4

   I have a few Auriou gasps in different sizes and grains, and they are wonderful. I have a couple of the Stewmac Dragon gasps, and I like them very much as well. Highly recommended.

4. 
   DRBWWing | Dec 08, 2020 11:04am | #5

   I don't have and $100 files to brag about, but you can't expect files to replace sandpaper, in fact, using them may increase the amount of sanding to remove file marks.

   I wouldn't touch end grain with a file, and I would use a roundover bit on the edges.

   You might try a sanding disc in the tablesaw.

   Explore the reason why you're having to do so much sanding.