Life as an Amateur Woodworker #4: Making a Bench Disc Sander

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Blog entry by PhilBello posted 10-25-2013 01:23 AM 4340 reads 1 time favorited 4 comments Add to Favorites Watch
« Part 3: Not everything goes to plan! Part 4 of Life as an Amateur Woodworker series Part 5: Sawdust everywhere! »

A Disc Bench Sander was next on the list, something simple, but effective was needed.

There are some excellent ideas on here, YouTube, and other sites, but my criteria, was that it could be run using my drill, and took up as little space as possible.

Well the final build could not be more simple, six pieces of wood, (1/2” ply to cut out the Disc, using my scrollsaw, and 3/4” ply for the Base, the Disc support, the Drill support and the two side pieces, one 8mm bearing ( an idea thanks to Izzy Swan, to stop the bolt wearing away the wood), a 5/16” x 3 1/2” bolt, one nut and two washers, a few screws and some glue. To make it work as advertised, I bought sheet sand paper and some spray glue ( the spray glue was the dearest item on the list costing nearly US$16).

I drew and cut out my parts using either the scroll saw or band saw, most of which came from the Mk 1 router table. I then did a dry fit to position the Drill support, and work out the height for the front disc support, which was governed both by the Disc size and drill height.

Once that was resolved, I drilled the Disc support to take the carriage bolt, and recessed and using epoxy, positioned the bearing, at the same time gluing a washer on the opposite side, between the two there is little chance of the bolt / spindle causing any wear.

The Disc itself, I drilled the centre, recessed the head of the bolt, and then using epoxy liberally I secured it with a washer and nut.

Again being aware that I needed to save space, I decided that I would not incorporate a wood rest, instead, I used the existing fences from both the Table saw and Router table, in different positions, I had a 90ยบ rest and also an angled rest.

Because of the 8” disc size, I bought sheet sand paper and cut it, each sheet giving me one disc and one piece big enough for hand sanding, and very little waste, this was then sprayed and attached to the disc.

The big question…Does it work, or did the Disc go flying into oblivion, I am happy to say that it works very well, I had no problems with the Disc, there is negligible vibration, and no noticeable wobble, so I happy with it.

As for what is next, I am going to make a supply of clamp / star knobs, for future projects.

-- If you want the rainbow, you got to put up with the rain - Steven Wright

4 comments so far

View Woodknack's profile


12887 posts in 2859 days

#1 posted 10-25-2013 05:08 AM

Nice project and if you ever get tired of the drill whine it should be relatively easy to switch over to a washing machine or fan motor.

-- Rick M,

View PhilBello's profile


411 posts in 2446 days

#2 posted 10-25-2013 11:27 AM

Thanks Rick, because I am in a ‘Micro-workshop’ at the moment, space is vitally important, so I am having to think outside the box, and see how things can be adapted by borrowing components from other tools to make things work. As you say at a later date a motor would probably be a better option.

-- If you want the rainbow, you got to put up with the rain - Steven Wright

View gfadvm's profile


14940 posts in 3169 days

#3 posted 10-26-2013 12:28 AM

Very clever and useful shop made tool! Those give me a lot of satisfaction when I use them.

You can buy 8” self adhesive discs if you choose to.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View PhilBello's profile


411 posts in 2446 days

#4 posted 10-26-2013 11:34 AM

gfadvm thanks, you are lucky, down here in Colombia, I pull my hair out trying to find anything, and self adhesive discs of any kind are so far evading my searches, they are all velcro or bolt on!

-- If you want the rainbow, you got to put up with the rain - Steven Wright

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