Reddit mentions of 3M Wetordry Sandpaper, Extra Fine 320 Grit, 9-in by 11-in, 5-Sheets (9086DC-NA)

Okay going to make this short and concise. These are all my opinions to make blades.

• Steel from here (start with 1084 or 1095 and you can either start with .156 or .187 for thickness (.187 is on the THICK side), or you can also get .125 thick for thinner projects. And 1.5 inches wide is the smallest i would go, or you can get 2 inches wide to be safe)
  
  
• Lots of different files, this one will help to start with though
  
  
  
• This belt sander does amazing to start out with
  
  
  Going to need lots of belts for it, here are some. Would suggest getting the 50 grit (please remember he will need multiple amounts of these so get a few of them). I would also suggest grabbing the 120 grit to take some deep scratches out. However the 320 isn't necessary as you can do all that by hand with regular sand paper.
  
  
• 1x30 50grit
  
  
• 1x30 120grit
  
  
• 1x30 320grit
  
  
  Hopefully in the yard or somewhere he can have a workbench set up because having a benchvise is such a luxury.
  
  
• This vice would do the trick
  
  
  
• The magical angle grinder, you can pick this up locally or order online
  
  
• It will need some of these
  
  
  Hand sanding paper (The fun stuff)
  
  
• 320grit
  
  
• 600grit
  
  
• 1000grit
  
  
  Also a sharpening stone will be very helpful however i don't have much knowledge as the best way to go with these. After doing some research, This stone seems like it would do the trick for the most part
  
  I forgot about these, 2 should be okay if he doesnt already have some
  
  
  Assuming you do not buy the 320 grit belts, and buy (5) 50 grit, and (5) 120 grit belts.
  
  The total comes to right around 308.36
  
  I failed you by breaking the budget, but your man is worth the 8 extra dollars :b Make him give you a foot rub and take you out for a nice dinner or something to repay the debt haha. GL and let me know if you have any other questions.
  
  Would like to note that all of this is for making the process easier. You can do all of this with 1 bench vise, 1 hand file, a hack saw and some steel. It would just take a long time and be extra tough! But absolutely doable without all of these gadgets

Plus one for /u/staff_guy comment. Get the teflon bushings and you won't have the sticking issue. Also, as you learned, the ca is unnecessary on acrylic and resin blanks. My 2 cents on micromesh is that it's a tad overpriced. FWIW Iwork with a lot of acrylics and resin. I typically use the following items and so long as you don't go too crazy they'll last a long time.

Large pack of 320 Grit as you'll use that the most to get your smooth shape down.
https://www.amazon.com/dp/B00004Z4BF/ref=cm_sw_r_cp_api_KOMiyb353ZW2H

A variety pack of 400-3000 Grit for polishing.
https://www.amazon.com/dp/B01JFX9UWQ/ref=cm_sw_r_sms_c_api_eLMiybQWJ11Q1

Lastly a small tube of tormek for final polishing.
https://www.amazon.com/dp/B00149DIBE/ref=cm_sw_r_cp_api_7SMiybBCXAV66

You'll spend about $25 and that setup will last you for many pens.