The best sanding block is one that matches the shape to be sanded. So recently when I had to sand some cove molding, I made some custom sanding blocks from 1½"- thick foam insulation. You can use a hand saw or a band saw to cut the shape. Here's how I made the blocks.
1. Trace profile
First butt the foam block against the molding and trace the profile.
2. Rough cut profile
Use a band saw (or hand saw and file) to cut the profile to rough shape.
3. Sand profile
Smooth the profile by rubbing it across a piece of sandpaper stuck to the workpiece.
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