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Finished my 12" Disc Sander

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  • Finished my 12" Disc Sander





    3/4 HP 3400 rpm motor scavenged from a combo belt/disc sander. Made the rest. The table is mild steel and the tooling slot matches my HF Tool Grinder so I can exchange tooling. I've already used the little miter gage.

    Table uses bicycle seat clamps, which work great:



    The bracket was rounded on the sander. The 80 grit wheel cuts that aluminum like butter. It took no time at all to round the bracket. I was pushing it hard and couldn't come close to stalling the motor. It's way overbuilt, so it is solid and a pleasure to use.

    I think I'm going to like this tool!

    I plan to use the rest of the parts from the original sander to make a heavy duty 2x72" belt grinder such as the knife makers like.

    Best,

    BW

    PS Full build log on my web site:

    http://www.cnccookbook.com/CCDiscSander.htm

    Also, thanks to all the others who published sander projects for inspiring me to get this done. You're credited at the end of the build log.
    ---------------------------------------------------

    http://www.cnccookbook.com/index.htm
    Try G-Wizard Machinist's Calculator for free:
    http://www.cnccookbook.com/CCGWizard.html

  • #2
    Looks great. Kinda inspires me to get my butt in gear and make the belt grinder I want.

    Comment


    • #3
      Very nice Bob! In case I missed it.. are those discs the "sticky back" kind?
      I have tools I don't even know I own...

      Comment


      • #4
        Looks good!Nice solid design.


        In case you have never used the stuff Formax makes an abrasive belt and disc grease stick that is the stuff to prevent abrasive loading and increase life,see here near bottom of the page-

        Formax Abrasive Belt Grease Stick

        No. 26 prevents clogging-- leaving the abrasive grit free to cut cleanly and
        smoothly. No. F-26 is recommended for all belt polishing operations-- on
        all metals, plastic and glass.

        http://www.abrasivesupplycorp.com/Ac...ubricants.html
        I just need one more tool,just one!

        Comment


        • #5
          Torker, yes the discs are "sticky back". I guess that's called Pressure Sensitive Adhesive?

          Weird, I had seen those sticks and wondered if they worked well. Guess I'll get a stick and have at it.

          Best,

          BW
          ---------------------------------------------------

          http://www.cnccookbook.com/index.htm
          Try G-Wizard Machinist's Calculator for free:
          http://www.cnccookbook.com/CCGWizard.html

          Comment


          • #6
            Further to what wierd said, any sort of cutting fluid will make aluminum cut much faster and leave a better finish. I use WD40 on my 12 inch horizontal grinder/sander. This is especially important when you have a lot to remove as the aluminum heats up a lot at the interface and becomes soft. Then it starts to gum up the paper and the finish is lousy. Lube stops that.

            Has anybody ever seen 12" emery disks instead of aluminum oxide? Emery lasts about three times longer in that service.
            Free software for calculating bolt circles and similar: Click Here

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            • #7
              Bob, if you want some drawings for the 2x72 let me know. I got them from a guy that built one like the KMG grinder, then posted his drawings on the web.

              I have mine started but need to finish it up:

              http://mattmorgan.org/gallery2/main....&g2_itemId=595
              http://mattmorgan.org/gallery2/main....&g2_itemId=598
              Last edited by mattm; 02-13-2008, 10:57 AM.

              Comment


              • #8
                Originally posted by mattm
                Bob, if you want some drawings for the 2x72 let me know. I got them from a guy that built one like the KMG grinder, then posted his drawings on the web.

                I have mine started but need to finish it up:

                http://mattmorgan.org/gallery2/main....&g2_itemId=595
                http://mattmorgan.org/gallery2/main....&g2_itemId=598

                I would be interested in the drawings if it is ok. I am thinking about how to build a 72 x 2 also. thanks.

                Comment


                • #9
                  Ok, I put the file on my site:

                  http://mattmorgan.org/KMG.pdf

                  One caution, I seem to remember finding a couple dimension errors that I annotated on my printed drawings but I didn't update the pdf file.

                  Matt

                  Comment


                  • #10
                    Matt, thanks for the posts.

                    I probably won't copy the KMG exactly, and will draw my own plans. I do kind of want to set it up so I can use KMG accessories if I want, but that's easy enough--just have to duplicate the arm dimensions.

                    As I often do, I am collecting a page of notes on these grinders before plunging in. Some of you may find it useful:

                    http://www.cnccookbook.com/CCKnifeMakingGrinders.htm

                    Best Regards,

                    Bob Warfield
                    ---------------------------------------------------

                    http://www.cnccookbook.com/index.htm
                    Try G-Wizard Machinist's Calculator for free:
                    http://www.cnccookbook.com/CCGWizard.html

                    Comment


                    • #11
                      Was the belt sander garbage or something? The reason I ask is that I have a combination 6x48 belt and 12" disk sander and find I use the belt regularly and almost never use the disk sander. I think this is in part because the disk is less than perfectly flat, but its also because you really only get to use less than one half of the disk area when sanding. Additionally, the rate of cut is variable across that 6" area....dropping to zero at the middle where the tangential velocity is 0. This doesn't make it a good tool for something you want to touch up but keep square. Moving the work back and forth helps with this, but I still find that the end toward the center is not hit as heavily.

                      On my long list of projects is to make another long-belt sander to dedicate to metalworking. In the mean time, I do have one of the cheap 1x30 Harbor Freight belt sanders I bought on sale for $29 as I recall. I use it a *lot* as its great for sharpening lathe tools. I bought some good, fine belts (down as fine as 400 grit) from a knife supply place and with them I can put a mirror finish on a lathe tool bit. When you want to just "touch it up" like you would normally do with a stone, just head to the sander and its done in a sec...without drastically changing things like center height as you would with a much coarser grinder. It also works nice for lots of other deburring tasks with say a 240 grit belt.

                      Paul
                      Paul Carpenter
                      Mapleton, IL

                      Comment


                      • #12
                        Put the disk horizontal and run it slow and suddenly a 12 inch sander becomes my most used sander/grinder. It makes it easy to keep things square and it doesn't eat the aluminum so fast that a touchup becomes a coverup job.
                        Free software for calculating bolt circles and similar: Click Here

                        Comment


                        • #13
                          BOB I should like to know how much the materials have cost on this as that aluminium looks expensive ?However the whole thing looks great as usual keep up the high standards you always produce .Alistair
                          Please excuse my typing as I have a form of parkinsons disease

                          Comment


                          • #14
                            What is the typical RPM for a disk sander? I need to decide which motor to use to build one. Good looking job, Bob.
                            Weston Bye - Author, The Mechatronist column, Digital Machinist magazine
                            ~Practitioner of the Electromechanical Arts~

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                            • #15
                              I think that 3450 rpm is typical, but I also think that slower is better. It won't cut as fast, but that's what they make grinders for. With a 12" disk being several dollars, having one gum up quickly is a downer. If you are building one from scratch, this is your chance to make a slow-speed sander.

                              I have an old one of the Grizzly combination machines as mentioned. I see they now offer it in a low-speed version (1750 RPM IIRC).

                              I didn't mean to be disparaging earlier, Bob. You truly did nice work!

                              Paul
                              Paul Carpenter
                              Mapleton, IL

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