This sander you all can AFFORD, but can't AFFORD TO BE WITHOUT, easy build.

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Project by bushmaster posted 05-08-2018 05:05 AM 8524 views 17 times favorited 27 comments Add to Favorites Watch

When I stopped by the local High School to pick up used bandsaw blades they gave me a number of 6 by 48 inch sanding belts that they no longer used. I have seen home made belt sanders that people have made here and Youtube. Always wanted to build one, no excuse now that I had some sanding belts of a certain size. I looked at a number of designs, some where just to complicated, I wanted something simple to build, yet very workable.

The only parts I needed to buy now was 4 – 6202 bearing for a 5/8 shaft size. A standard 6202 has a metric size shaft size. this bearing is great as by using a 1 3/8 forester bit the bearing can be pressed into the hole. and a length of 5/8 shaft, 20 inches is enough, The first one I build I happened to have a piece that was salvaged from something else.

The wood parts are just some scrap plywood to make the rollers and two pieces of hardwood for the sides, and a small amount of plywood to separate the sides. Oh yes how could I forget two 1/4 inch bolts,

What makes this belts sander simple to build is the tension and tracking mechanism, The bearing are installed in the front roller, the shaft can now be drilled and tapped for a 1/4 inch bolt, they will tension and are used for the tracking, If you don’t have a tap, drill 1/4 inch hole right through and the a larger hole on the back side and press in a 1/4 inch nut. I had to do that on the second one I build as the stainless steel was too tough to cut the threads.

I made the rollers 3 inches, they must be flush with the top of the sides, front one crowned and the rear one flat, the box separating the sides need to be at least a 1/4 inch less that the height of the rollers. The width of that box will be wider than the belt. The ;bearing as dI said is installed in the from roller and must be spaced so it centers between the sides, for this I used a large washer and then some small one next to the bearing. the rear one can be spaced with small washers as the bearings are in the side boards.

My plan was it to have its own motor, and still can and you might want to build one that way, but I wanted to try it out and I thought why not adapt it to the wood lathe, strong motor and already was set up for multiple speeds, What makes this sander great or better than bought ones is that you can run it at slower than 3450 rpm half that speed has advantages, build one and you will find out quickly.

So this is how I did it. Drive was made by using a faceplate and block of wood. drilled on the lathe for the shaft size , a slot for the pin on the shaft.

The drive shaft has to be center drilled as it is supported by the live center on the tail stock. now we just need a support for the roller end and a dust pick up. Support was done by using the tool post holder.

Two types of dust pickups, one for sanding long pieces or lager flat surfaces, the slower speed allows you to hold on to your work safely. The dust pick up are held in place by the the force of the air. no dust escapes.

And one with a stop to do all your other sanding needs, the stop has extra holes in it

Wow that was allot of pictures and information to wade through and think about. I made a video to give you an overview and a demonstration. View it at

I will be leaving for 3 to 4 weeks be participate in a volunteer construction project as I have done other years, I will post a basic plan as soon as I can, I will be two days on the road but will be checking in and answering any questions you might have. I really find this unit useful, quiet, safe, and joy to use.

Thanks for watching and comments are appreciated.

-- Brian - Hazelton, British Columbia

27 comments so far

View ZAGREB's profile


1276 posts in 2526 days

#1 posted 05-08-2018 05:33 AM

great job,buddy

-- bambi

View Dutchy's profile


3819 posts in 3045 days

#2 posted 05-08-2018 05:48 AM

View Ivan's profile


16292 posts in 3744 days

#3 posted 05-08-2018 08:49 AM

Great inspireing mashine! I agree on titled statement.

-- Ivan, Croatia, Wooddicted

View recycle1943's profile


4784 posts in 2499 days

#4 posted 05-08-2018 10:12 AM

great build and very useful

-- Dick, Malvern Ohio - my biggest fear is that when I die, my wife sells my toys for what I told her I paid for them

View hunter71's profile


3533 posts in 4063 days

#5 posted 05-08-2018 10:57 AM

Looks like it should do the job nicely.

-- A childs smile is payment enough.

View BobWemm's profile


2885 posts in 2803 days

#6 posted 05-08-2018 11:55 AM

Great idea and build Brian.
Thanks for sharing it with us.


-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

View Jim Jakosh's profile

Jim Jakosh

25277 posts in 3982 days

#7 posted 05-08-2018 11:59 AM

Nice new sander, Brian! No extra motor needed either!! I have a group of 6202 bearing sitting on the back of the bench in the barn. I wish I knew you needed them when you were down here.

Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View helluvawreck's profile


32122 posts in 3743 days

#8 posted 05-08-2018 12:23 PM

You did a very nice job on this shop made sander. Congratulations!

-- helluvawreck aka Charles,

View bushmaster's profile


3953 posts in 3159 days

#9 posted 05-08-2018 12:56 PM

Woke up at 4:30 and couldn’t sleep so got up and made th

is basic plan

-- Brian - Hazelton, British Columbia

View GR8HUNTER's profile


7896 posts in 1589 days

#10 posted 05-08-2018 01:57 PM


-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN :<))

View PaulDoug's profile


2394 posts in 2580 days

#11 posted 05-08-2018 03:46 PM

That is a great sander. Nice job.

-- “We all die. The goal isn't to live forever; the goal is to create something that will.” - Chuck Palahniuk

View lew's profile


13188 posts in 4632 days

#12 posted 05-08-2018 04:04 PM

Awesome project!!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View ralbuck's profile


6595 posts in 3143 days

#13 posted 05-08-2018 04:06 PM

GREAT JOB :<))Your usual innovation showing too!


AH Brian, Now stand it upright for many jobs. You can build a vertical one. I stoof my Jet vertical the first day on the shop and have never lain it flat since.

-- Wood rescue is good for the environment and me! just rjR

View bushmaster's profile


3953 posts in 3159 days

#14 posted 05-08-2018 04:18 PM

Ralbuck If you stand it up, one would have to go to the otherside of the lathe, or one would need to make a sanding plate on the bottom too, since you are not running it at high speed, 3450, I am sure it would be ok. I had left a gap sat the bottom on this one for cooling. As this one can run at a slower speed than most bought ones, I find it much superior. Most of my work I like it flat, I have a large commercial one that I use edge vertical. I can move it to a horizontal position too, might work better for me too.

-- Brian - Hazelton, British Columbia

View kaerlighedsbamsen's profile


1346 posts in 2590 days

#15 posted 05-08-2018 04:50 PM

Clewer solution and nicely executed. Enjoyed the video as well.
Thanks for sharing!

-- "Do or Do not. There is no try." - Yoda

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