How to Get Plywood Extra Smooth Using Sandpaper?

How to Get Plywood Extra Smooth Using Sandpaper

Plywood stands as a cornerstone in various industries, from construction to furniture making and crafting. Composed of thin layers of wood veneer glued together, plywood offers exceptional strength, versatility, and durability, making it a preferred choice for a myriad of applications. To achieve the desired smoothness, the process often begins with the use of sandpaper. Sandpaper serves as a versatile tool in the woodworking arsenal, capable of refining rough surfaces into silky-smooth finishes. In this guide, we delve into the nuances of using sandpaper to attain that coveted extra smoothness, equipping you with the knowledge and techniques necessary to elevate your woodworking endeavors to the next level.

Grades and Types of Plywood

Plywood comes in a variety of grades and types, each tailored to meet specific needs and standards. Grades are designated based on the quality of the face and back veneers, as well as the presence of defects such as knots, voids, or patches. Common grades include:

A-Grade: These plywood sheets feature a smooth, sanded surface on both sides, with minimal imperfections. They are ideal for applications where appearance is crucial, such as furniture, cabinetry, or architectural millwork.

B-Grade: B-grade plywood may have minor defects such as knots, patches, or discoloration on one side, while the other side is relatively smooth. This grade is suitable for structural applications where appearance is less critical, such as subfloors, roofing, or sheathing.

C-Grade: C-grade plywood exhibits more noticeable defects and imperfections on both sides, making it suitable for rough construction purposes where appearance is of little concern. It is commonly used for temporary structures, packaging, or as a substrate for exterior siding.

D-Grade: D-grade plywood features a rough surface with numerous knots, voids, and patches on both sides. This grade is primarily used for applications where structural integrity is paramount, such as concrete formwork or temporary bracing.

Choosing the Right Sandpaper for Plywood Smoothing

Aluminum Oxide: When it comes to smoothing plywood, aluminum oxide sandpaper is a top choice. It’s tough, lasts a long time, and comes in different roughness levels. Whether you’re sanding by hand or using a machine, aluminum oxide gets the job done efficiently without getting clogged.

Silicon Carbide: Another great option for plywood smoothing is silicon carbide sandpaper, especially for those finishing touches. It’s got sharp grains that work quickly and leave surfaces smooth on both hard and soft woods. Plus, it’s perfect for smoothing between coats of finish for that flawless look.

Zirconia Alumina: While not as popular for plywood, zirconia alumina sandpaper is tough and cuts well. It’s perfect for heavy-duty tasks like shaping and removing a lot of material. If you’re dealing with tough plywood surfaces, zirconia alumina can handle rough sanding with ease.

Sanding Techniques for PlywoodSanding Techniques for Plywood

Hand Sanding vs. Machine Sanding

When it comes to sanding plywood, you’ve got two main options: hand sanding and machine sanding. Each has its pros and cons:

  • Hand Sanding: Hand sanding gives you more control and precision. It’s great for smaller projects or detailed work where you need to focus on specific spots. You can feel surface imperfections better and adjust your pressure for better results.
  • Machine Sanding: Using tools like orbital sanders or belt sanders, machine sanding is faster and more efficient. It’s perfect for big projects or flat surfaces. Machines cover more ground quickly and give consistent results, but you have to be careful not to over-sand or press unevenly.

Sanding with the Grain vs. Against the Grain

When sanding, you can go with the grain (parallel to the wood fibers) or against it. Here’s the deal:

  • With the Grain: Sanding with the grain is better because it reduces the chance of scratching or tearing the plywood. It helps the sandpaper remove material evenly, giving you a smoother finish.
  • Against the Grain: Sanding against the grain can cause splintering, especially on softer plywood. But sometimes, you gotta do it to fix stubborn spots. Just use finer sandpaper and go easy to avoid messing up the wood.

Circular vs. Back-and-Forth Motions

There are two ways to move your sandpaper: circular or back-and-forth.

  • Circular Motions: Going in circles spreads out the pressure and stops you from leaving marks. It’s perfect for big, flat surfaces where you want a smooth finish.
  • Back-and-Forth Motions: If you’re fixing up specific spots, go back and forth in straight lines. Just keep the pressure even and the direction consistent to avoid making any marks.

Tips for Getting a Smooth, Even Finish

Getting your sanding just right is key to a polished look. Here’s how to do it:

  • Keep It Steady: Apply the same pressure and movement the whole time to avoid uneven spots or taking off too much material.
  • Overlap Your Strokes: Make sure each pass overlaps the last to cover every bit and smooth out imperfections evenly.
  • Check Often: Keep an eye on the surface to see if it’s smooth and consistent. Adjust your technique or switch sandpaper grits if needed.
  • Clean Up: Keep your sandpaper tidy to stop it from getting clogged and keep it working well.

Achieving Extra Smooth PlywoodAchieving Extra Smooth Plywood

To achieve an exceptionally smooth finish on plywood, several advanced sanding techniques can be employed:

Gradual Sanding Process:

Begin by using coarse sandpaper, like 120-grit, to smooth out any bumps or unevenness. This initial step levels the surface and eliminates rough spots. Then, switch to finer grits such as 220-grit and 320-grit to refine the surface further, removing smaller imperfections and scratches left behind. Each stage of sanding progressively improves the surface, resulting in a flawlessly smooth finish ready for the final touches.

Sanding Between Coats (Optional):

For those aiming for an extra-smooth final look, sanding between coats of paint or primer can make a real difference. It’s a handy trick that helps smooth out any small imperfections, brush strokes, or drips, giving your project a polished, pro finish. To know when it’s time to sand between coats, just follow the drying time listed on the product, usually around 24 hours. Once the coat feels dry to the touch but isn’t completely set, gently sand the surface with fine-grit sandpaper, like 220-grit, to tidy up any flaws. Make sure to clear away any dust or debris before adding more coats for the best adhesion and finish.

Sanding Curved Surfaces:

When you’re sanding curved plywood surfaces, like rounded edges or contours, special sanding tools are key. Things like sanding sponges or conforming sanding pads are super helpful. Sanding sponges are flexible and can mold to the shape of the surface, so they’re great for getting an even sand across curved areas. Conforming sanding pads have a soft foam backing that shapes to the contours, giving you consistent pressure and sanding. When you’re sanding curves, go easy with light pressure and gentle circular motions to avoid flattening or changing the shape. Make sure to keep things smooth and even to avoid any weird bumps or uneven spots on the curved surface.


In conclusion, achieving an extra smooth finish on plywood requires patience, precision, and the right techniques. By employing a gradual sanding process, considering optional methods like sanding between coats or wet sanding, and addressing curved surfaces effectively, craftsmen can elevate the quality of their woodworking projects. Whether crafting furniture, constructing cabinets, or engaging in DIY endeavors, mastering these sanding techniques ensures a flawless and professional result that enhances the beauty and durability of plywood creations.

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