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When trying to make a drill powered disc sander, connecting the sanding disc axis directly to the drill chuck, I realised it was not a good idea. The problem is that there is always some play in the drill chuck, and that affects a lot to the sanding disc movement. So I decided to make a shaft with bearings. And I will put it between the sanding disc and the drill chuck making a kind of sanding attachment for drill. So let’s see how to make this homemade disc sander using the shaft with ball bearings.

Drilling a hole to house the shaft bearingsFirst I have to make a new drill support. But well, instead of a drill support I will make a shaft support. So I cut four plywood strips and I glue them in pairs to make two pieces. Now I clamp those two pieces together. And I use a forstner bit to drill a hole to house the bearings. I have to drill a precise and vertical hole, so I use the drill press.

How to install the shaft in the supportSo, I screw one of those two pieces to a small plywood board. And now I can install the shaft with bearings. The hole I drilled is some smaller that the bearings, so I have to put two pieces of cardboard so the shaft fits,.

Making the disc sanding attachment for drillAfter checking that the shaft turns correctly, I can install the drill. And now I can use some epoxy, washers and nuts to install the first plywood disc to make this disc sanding attachment for drill.

I used my DIY circle cutting jig to cut this plywood disc. And I drilled a hole in the centre of the plywood circle. That hole is the same diameter as the threaded rod in the shaft with bearings. Like this I can screw it in the threaded rod.

Cut the protruding threaded rodAnd I cut the part of the threaded rod that protrudes the nut.

Now it is time to rectify the plywood disc. And this is the most difficult part. I put a simple wooden table in front of the disc (this is the same table I will use when working with this disc sander), and I use a chisel, or a gauge, to rectify the disc. I try to make it be perfectly at 90 degrees with the shaft, but trying to keep it perfectly flat. I also rectify the back of this disc sanding attachment for drill so it is the same thick all around. Otherwise it will vibrate a lot.

Rectify the front of the disc sander disc
Rectify the back of the disc sander disc

The hole and the counterbore to hide the nutOnce I rectified it, now I glue a thinner disc. This one will hide the nut that protrudes the front of the first disc. So I had to make a hole and a wide counterbore to accommodate the washer and the nut.

Then, I glue the thinner plywood disc, and I clamp it while the glue dries. To do this it is better to disassemble the shaft with bearings so I can clamp both discs together with several clamps. And once the glue dries I use some wood paste to fill the hole in the front of the disc. I let it dry and I sand it flat. Finally I rectify the edge so both discs are identical.

Clamping together the parts of this sanding attachment for drill
How to rectify the edge of the disc sander

Now I just have to cut a piece of sandpaper that has the same diameter as the plywood disc. And I use stencil adhesive to stick it to the plywood. I use medium grit sandpaper, because it is the kind of sandpaper I use most often. And it works well to shape the wood.

Some people ask about how to change the sandpaper of this disc sander. And the truth is that, because I use stencil adhesive, it is very easy to remove the old sandpaper. Maybe it will be even easier if I heat it with a heater gun. But I didn’t try that yet.

Cutting and gluing the sandpaper disc
Using spray stencil adhesive to stick the sandpaper

Sanding with the homemade disc sanderI install this disc sanding attachment for drill again in the support, and now I can use my homemade disc sander to sand wood or plywood.

After some time using this DIY disc sander, I am really happy with how how works. It is very easy to sand with a lot of precision, so it is a must have in our woodworking shops.

Gracias por compartir :D

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