So I had this idea to either cut or sand a LEGO bandanna (http://www.bricklink.com/catalogItemPic.asp?P=x70) so that I was left with a head band that could be attached to a modified hair piece (likely going to be the BF hero hair). Given the size of the piece, sanding the part from the top down seems most feasible. Is there a certain grade of sandpaper that folks would recommend?

If you are wondering what it is I'm trying to do, look at this tutorial from the old Minifig Customization 101 series that appeared in BrickJournal a few years back (http://www.fineclonier.com/Parts_Modification.pdf). Its a variation on the theme of hair and hat combo shown on the fourth page.

Thanks!

I'd recommend the highest grit, if you don't have a dremmel. Then switch to a lighter one when you get to around the end, that'll smooth it down and I've heard that makes glueing easier.

Hmm, the page wouldn't open for me.

It's a pdf. Do you have Adobe Acrobat or another file that reads pdf's?

Yes, I do ... hmm, I'll try it again.

Hmm, not sure why it didn't open before ... but I've used sandpaper - very fine, and lightly; but I've found that running my xacto over the edges I've cut (that I want smoothed out) works real well. It will lightly shave the surface as you work around and finish the shape you want with not scratches.

There is a tutorial by Armothe regarding cutting and gluing in the Armory too, very similar and very good: Intro to Part-Fusing
I still need to get a couple of things, but hope to do this very soon.

Ha! Thanks for the reminder about Armothe's tutorial. I had an article that linked to it around the time the pics of the TLG Cad Bane came out as an example of part modding.

The old memory isn't what it used to be...