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I have only done it once, but used sandpaper on a flat surface (granite slab) and sanded by hand. I use digital calipers to check thickness. You have to make sure that you are holding the bone flat and not rocking it while sanding. The nut needed a lot of material removed so I started with a belt sander but you have to be careful because its easy to take off too much or get it out of square.
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Ah well, there was a fantastic passion there, in my case anyway. I discovered flamenco very early on. It grips you in a way that you can't get away - Paco Pena
I took a piece of 3/4" MDF and made a channel in it, wide enough for a saddle blank, on my table saw and glued a piece of wood in it to keep the blank from being pushed out one end. Then I place the blank in the channel and run the whole thing through my drum sander, lowering the drum a little at a time. I did the same for nut blanks. I drum sand to very close to final thickness and do the rest by hand, rubbing the blank on pieces of sand paper lying on the bench.
I stick a row of them to parcel tape & feed them through the drumsander, once they are level with one another I add another piece of tape to the other side of the nuts, flip it over & remove the first piece of tape, then feed them through again. I use a piece of scrap top to shovel them onto the conveyor belt & scoop them off again as they come through. A calliper can be used to measure the progress without having to remove the tape. Once near to correct thickness I finish them off by hand.
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