A disc sander machine is most commonly implemented as a stationary machine that consists of replaceable circular shaped sandpaper attached to a wheel turned by an electric motor. The usually wooden work piece, although other materials can be shaped and worked on such as plastics, metals and other material. Work piece is sat on a front bench that can be adjusted to various angles.
Disc sanders are extremely useful tools in workshop used for rough shaping wood. When I needed a dedicated sander that could take off a lot of material at once, I was less than impressed with what was available in market in my price range. After not finding any disc sanders with the size and power I wanted in my price range, I started thinking of other options. I already made disc sanders in the past, but this was different. Most did not include a tilting work surface. This was a great design challenge that turned out better than I could have hoped!
There are many motors out there that are suitable for a disc sander. However, free motors are the best motors. If you can find any motor second hand, that would be best for this project. You want to find a motor that is at least 0.5 HP. Make sure that you know what way your motor spins before making this project. Most motors are reversible, but not all. The motor I used runs clockwise.
If you are looking for your own disc sander machine and not impressed with anything available for the price in market, a homemade disc sander may be for you.
Parts Used :
0.5 HP electric motor 1440 rpm
2Nos. plywood 19 mm thicknesses (20”*11”) for base
4Nos. plywood 19 mm thicknesses (6.5”*11”) for motor base
9 inch diameter circle plywood 19mm thickness for disc
Laminated plywood piece (6.5”*11”) for work surface
Other plywood pieces
V-Belt pulley 3 inch
2 Nos. 1inch L-Section metal angles (13.5” length)
Metal sheet pieces
Velcro paper disc 60 grid
4 Nos. 5/16 bolts with nuts (5” length) for motor support
1 inch PVC elbow for vacuum attachment
2Nos. 5mm allenky bolts (1” length)
4Nos. 8mm allenky bolts (1.5” length)
4Nos. 6mm counter sunk allenky bolts (1” length) for attach disc
Glue, screws and nails
How to make :
First step to make this disc sander machine is cutting all necessary plywood parts. I used 2Nos. plywood 19 mm thicknesses (20”*11”) to make base of this sander machine and 4Nos. plywood 19 mm thicknesses (6.5”*11”) for motor support base.
First attach the 2Nos. plywood 19 mm thicknesses (20”*11”) in parallel using of glue and screws, to make base of this sander machine
Then attach 4Nos. plywood 19 mm thicknesses (6.5”*11”) in parallel on the base using of glue and screws to make motor support base.
Attach, 0.5 HP electric motor on the motor support base by using of 4 Nos. 5/16 bolts with nuts (5” length). Make sure that you know what way your motor spins before making this project. Most motors are reversible, but not all. The motor I used runs clockwise.
Cut the 9 inch diameter circle plywood 19mm thickness to make disc of the sander. I have used circle cutting trimmer jig to cut the perfect 9 inch diameter circle.
Attach this 9 inch diameter disc to 3 inch v-belt pulley. I have used 4Nos. 6mm counter sunk allenky bolts (1” length) to attach disc with pulley.
Attach this disc and pulley on the motor shaft. Make sure that the disc was not wobbling. If the disc wobbles, you will have uneven wear on your sandpaper.
I have used 2 Nos. 1inch L-Section metal angles (13.5” length) to move the worktable in and out towards the sanding disc. So, first of all make a slot on both these L-Section angle, and then attach these angles on the base by using of screws, as shown in the image.
Next step is to make work table of this disc sander. This worktable has two functions. First it is movable (slides) and second, it has tilting work surface.
So, first we have to make movable section. I have used plywood pieces, MDF sheets to make this movable section.
Next we have to make tilting surface section. I have used laminated plywood piece (6.5”*11”), metal sheets and allenky bolts to make this tilting surface section. Cut the metal sheets in the shape, and make perfect slots in both metal sheets, as shown in the image. Tilting capacity of this work surface is up to 45 degree.
Attach this worktable with the base through L- Section angle using of 8mm allenky bolts.
I have used the metal knobs to fix the position of the work table, as shown in the image. To make these metal knobs I have used scrap material.
Attach 1 inch PVC elbow for vacuum attachment. This PVC elbow used to attach with the vacuum cleaner machine. This dust collection system will allow for simple removal of the dust and other waste particles.
Attach ON-OFF switch.
Attach valcro belts on the disc using of glue. Let the dry the valcro for 1 day. After that, attach the valcro sand paper with the disc. The main advantage of this disc sander is that the sand paper is easily replaceable.
Now, the disc sander is ready to use. This sander is useful for wood, metal and other soft material.