Some years ago, Allen Brickhaus showed me a sanding block that was made from 5/8" siding foam. I bought a 4 x 8 sheet of the blue foamboard from Home Depot and it supplies enough blocks for a lifetime. I have bought self adhesive rolls of sandpaper (2 3/4" wide) and cut my foam blocks the same width and about 4" long. All you have to do is press the sandpaper to the foam block and trim the edges. Another thing you can do is just use sheet sandpaper cut to the appropriate size and spray 3M77 adhesive on the back of the sandpaper and press onto the block. Either method works very well.
I am currently looking for a good source of the self adhesive sandpaper rolls that are reasonably priced. Does anyone have a source for these. I would like to use 3M brand but cant find rolls with the adhesive back, only their stikit pad system.
Thank you
Mike