I’m currently working on a solution to this problem without manually having the tedious task of cutting each and every square of sand paper glued to the disc. It’s such a waste to only be able to use the outside 1/4 of an inch or less. I found out I didn’t have the patience to cut each flap and if you factor in your time, it’s cheaper to buy a new one. At one time there was a company that produced some kinda flap disc that was trim-able, but I’ve not been able to find them. Personally, until i find an efficient way to revive a flap discs, I’ve switched to Resin Fiber disc. I think they work just as good-if not better, they’re durable, and cleanable with a wire brush or wheel. An even better solution- although more expensive- is a shaping disc. You can find these at your better woodworking retailers. They’re technically produced for carving applications but work great on any wood project as long as you’re working nail and metal free.
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