This is a rather simple idea, yet maybe you never thought of it.
After a club member run my beam of lime wood through his bench saw, the resulting longerons had some diverse thickness and slight bites of the saw blade. Here's what I do when I need some precision sanding. I tape little blocks with the correct thickness to the ends of my sanding block (on top of the sanding paper). The sanding is done on smooth MDF board, holding the work piece flat. First I check the result on a piece of scrap; if necessary I do some fine adjustment by adding tape. I use very coarse sanding paper (.80), stuck to the sanding block with Gudy 870. It's fast, easy and very precise.
Never lift the working piece or the sanding block from the board and use your vacuum cleaner a lot, so no dust gets under it.
With some imagination and customized sanding blocks you can also use this as a manual alternative to milling and sand accurate notches and gaps (... for those who don't have the money or space for machinery).
Tip Submitted By: Henri Kaper, Netherlands