Some time ago I decided to make my own disc sander using an old motor I've had for years, it was a rainy day project inspired by various designs on YouTube.
I cut the sanding disc from 18mm birch ply using a router with a simple circle cutting jig
My first challenge was solving how to connect the motor drive shaft to the sanding disc and it was then that @Phill05 came to my rescue and kindly made me a perfect flange.
I then made the disc housing from 4 semi-circles of 18mm birch ply, this involved a fair bit of trial and error using thinner, cheaper ply I had in until I was happy with the two radii.
I then glued all the segments together and added two straight sides and an 18mm backing plate.
I then added a base with stabilising legs onto which I made a support stand out of stacked 18mm offcuts to raise the motor to the required height.
I bought a NVR Switch and made a ply surround for it, connecting both power cables with strain relief cable glands.
I then built a tilting table with stops gauged at the horizontal and a gauged 45 degree tilt that stops at the base.
I then cut a hole in the other side of the backing plate for the dust extraction hose
.
A final sand and varnish with 2 coats of Ronseal Diamond and also machine wax on the table. Very pleased with it, it works perfectly.
I've now decided to make a mitre gauge for it as off the shelf ones are too big. I have some spare track and have ordered a 100mm mitre rail.
I cut the sanding disc from 18mm birch ply using a router with a simple circle cutting jig
My first challenge was solving how to connect the motor drive shaft to the sanding disc and it was then that @Phill05 came to my rescue and kindly made me a perfect flange.
I then made the disc housing from 4 semi-circles of 18mm birch ply, this involved a fair bit of trial and error using thinner, cheaper ply I had in until I was happy with the two radii.
I then glued all the segments together and added two straight sides and an 18mm backing plate.
I then added a base with stabilising legs onto which I made a support stand out of stacked 18mm offcuts to raise the motor to the required height.
I bought a NVR Switch and made a ply surround for it, connecting both power cables with strain relief cable glands.
I then built a tilting table with stops gauged at the horizontal and a gauged 45 degree tilt that stops at the base.
I then cut a hole in the other side of the backing plate for the dust extraction hose
.
A final sand and varnish with 2 coats of Ronseal Diamond and also machine wax on the table. Very pleased with it, it works perfectly.
I've now decided to make a mitre gauge for it as off the shelf ones are too big. I have some spare track and have ordered a 100mm mitre rail.
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