Homebrewed disc sander

Hey Gang,

Some of you may have seen this in the OT forum, but it came out well so I thought that I'd post it here. Hope that this inspires someone.....

Short story...I needed a sander and was short on cash. I had a 1/3hp@1725 motor and an assortment of raw material to choose from. All I had to buy some self-adhesive sanding discs, a switch box & cover, a new plug for the end of the cord, and some crutch tips for the feet.

The motor was a "Laundry Motor" according to the label. On it's shaft was some sort of threaded collar with a hex head on it. I used this as a starting point. I machined a piece of 2.25" brass round to press fit onto this collar and on the other end made a 1/4" "nose" to align the aluminum disc. Four 10-32 screws hold the disc to the brass collar.

The frame for the motor was simply some 1/2" square and 3/4" angle that I had. I used a piece of 2"x2" angle and some large hose clamps to mount the motor. The motor is bolted to the rest of the frame, and is adjustable all ways to ensure that it is up against and square to the table. The table itself is a piece of 1/4" aluminum plate notched to fit around the sanding disc. I decided against making the table adjustable because 98% of what I will do with it does not involve compound angles. Besides, I can always make a jig if the need arises.

The only things not pictured are the addition of a regular light switch, and some rubber crutch tips on the feet to help keep the noise down. It runs smoothly, sands a perfect 90*, is quiet, and the vibration is minimal. At some point, I may add a dust catcher under the table. Not bad for under $20.

 

Thanks Thad. That gives me some ideas. I may try to make something similar.

 

Very nice. Where did you get the disk? I made one years ago out of an old evaporative cooler motor but it didn't work all that well. Mounted on a plate welded to a piece of pipe welded to an old dually wheel. I used a large piece of angle iron as the table, welded to the pipe. You may have inspired me to re-work it. It would make my projects look much more professional.

In my spare time.

Whenever THAT is. R)

 

Disc was a large piece of plate aluminum that I had to cut the disc out of with my plasma cutter. You could do it with a regular bandsaw if you get the speed down. I REALLY miss having a bandsaw for brass and aluminum!

 

I think Thad should start his own TV show...
"How To Make Something Out Of Nothing"
or
"You To Can Do It"
nice idea and good workmanship Thad !

 

Actually Jim, I was thinking more along the lines of "How to get the tools you need when you're stinkin' broke." Or at very least a spot on "Junkyard Wars" or "Monster Garage". R)

Believe me, when I had the shop, I wouldn't think twice about spending reasonable sums of money for tools/equipment. Now that I'm in emploment purgatory (hopefully soon to be a better situation) I have more time to make the stuff, but no money. What got me going on this project is that I have some guitar work that I will need the sander for.

And if you think this is "something from nothing", wait until I get enough $$$ to buy stove pipe for the woodburning stove I'm making from an old water heater. R)

 

dang
one of the networks should be picking up on this.....
just remember your roots when stardom finally arrives.

 

Judging from what I've seen of you on here, you'd have been a good candidate for either of those original shows, before they turned into soap operas. (I've never met you and am assuming you're not a lazy lout always conspiring against your coworkers. R) ) At least MythBusters is hanging in there, although they too are leaning toward more showy production values these days. I just like to see someone figure something out or build something. Old Bill, you've got my TV-viewing vote.