Home made Disc Sander

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Project by Jeff posted 06-06-2010 12:07 AM 86032 views 75 times favorited 33 comments Add to Favorites Watch

I wanted a way to sand outside corners smoothly and quickly. Looking through one of Danny Proulx’s books I came across his plans for this DIY version. Went scrounging at my local machine repair shop for a used motor with the right RPM and found one for a bargain price. Everything else is 3/4” plywood put together with pocket screws. There is a dust collection port under the motor and I wired it to a simple ON/OFF light switch.

The hardest part was fiddling with the actual plywood disc and the cheap pulley to get it perpendicular to the motor shaft. If you had access to machined pulleys they would make a better choice. You also want to use the flattest piece of ply for the disc.

On the piece of plywood is a adhesive backed piece of hook and loop. And then you just slap on a felt backed circle of sandpaper and voila!

-- Jeff

33 comments so far

View mtkate's profile


2049 posts in 4605 days

#1 posted 06-06-2010 12:09 AM

I like Danny’s books. He is very practical.

View bake's profile


389 posts in 4957 days

#2 posted 06-06-2010 12:21 AM

Jeff, what is the proper speed and what is the diameter of the disc?
BTW nice job!

-- I love the smell of Home Depot in the morning, it smells like.......carpentry. Bake, Bar Lazy U Woodworks, Lehi,UT.

View Dusty56's profile


11866 posts in 4967 days

#3 posted 06-06-2010 12:26 AM

Great job on this sander : )

-- I'm absolutely positive that I couldn't be more uncertain!

View a1Jim's profile


118296 posts in 4857 days

#4 posted 06-06-2010 12:28 AM

Coolness prevails great job.


View woody57's profile


650 posts in 4707 days

#5 posted 06-06-2010 12:42 AM

I have some old motors. I need one of these. Where did you get the hook and loop material and the sandpaper disk?

great job btw

-- Emmett, from Georgia

View BarryW's profile


1016 posts in 5186 days

#6 posted 06-06-2010 01:09 AM

Since i don’t have one…thanks for the idea

-- /\/\/\ BarryW /\/\/\ Stay so busy you don't have time to die.

View NormG's profile


6574 posts in 4283 days

#7 posted 06-06-2010 01:22 AM

It has it all, pocket screws, dust collection and adjustable table. Great job

-- Norman - I never never make a mistake, I just change the design.

View Jeff's profile


116 posts in 4194 days

#8 posted 06-06-2010 01:26 AM

It is a 12” disc. Adhesive backed hook and loop, and felt backed abrasive disc are from

Motor RPM is 1725

-- Jeff

View ChunkyC's profile


856 posts in 4534 days

#9 posted 06-06-2010 02:09 AM

I started gathering parts this week to build me one these. Congrats on yours! I was snooping around for ideas and dims.

I’m going to try a “Quick-Disconnect Bushing” from McMaster-Carr in lieu of the pulley, McMaster P/N 6086K197. Don’t know if it’ll work or not, but it only costs $12.25 so not out much if it goes bust.


-- Chunk's Workshop pictures:

View moondog69's profile


96 posts in 4220 days

#10 posted 06-06-2010 02:44 AM

i like it,good job

-- al.chazy ny

View woodworm's profile


14477 posts in 4870 days

#11 posted 06-06-2010 04:48 AM

Great idea and effort! Thanks for sharing.

-- masrol, kuala lumpur, MY.

View twokidsnosleep's profile


1130 posts in 4253 days

#12 posted 06-06-2010 05:29 AM

Very resourceful….love it

-- Scott "Some days you are the big dog, some days you are the fire hydrant"

View Joel Wires's profile

Joel Wires

16 posts in 4471 days

#13 posted 06-06-2010 05:44 AM

Simple yet awesome. I’ve got a couple of extra motors laying around that I was trying to figure out what to do with them… here is my answer. Very nicely done.

-- Joel Wires -->

View ifixbmws's profile


14 posts in 4193 days

#14 posted 06-06-2010 05:58 AM

well i know what tommoro nights project is now!... thanks!

-- man dovetails make welding look easy!

View gul's profile


400 posts in 4242 days

#15 posted 06-06-2010 07:11 PM

Very useful,great job. Can anyone tell can a bench grinder be used as disc sander?

showing 1 through 15 of 33 comments

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