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Drum Sander #2: Fixing a hole

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Blog entry by BritBoxmaker posted 05-14-2010 01:55 PM 2041 reads 5 times favorited 15 comments Add to Favorites Watch
« Part 1: From Micro to Macro Part 2 of Drum Sander series Part 3: Zen and the art of Bandsaw Drum part making. »

Hello again, fans of the drum sander.
Yesterday I wrestled home an 8’ x 2’ sheet of 3/4” MDF. I am one of those fortunate to be at school when the metric system was being introduced so I can still speak imperial, which is lucky as the plans for this thing are American in origin. The plans call for 3/4” ply for the table and drum parts but I have decided (he’ll regret it he always does when he makes these assertive decisions) that MDF is going to be more appropriate for this project. Two reasons.

1. MDF has a nice flat, smooth surface. I tried oiling up an offcut

and I can see no reason this can’t be used for the working surface of the table. Again the design call for a layer of Formica. Whilst this IS available here no regular outlet wants to sell you less than a 5’ x 10’ sheet and I can’t be arsed (English slang – bothered) to grub around for an offcut, not even on Ebay. Anyway if the surface gets scuffed up, with wear, I’l put a layer of hardboard on it. If that gets trashed then (and only then) will I seek out Formica. So there.

2. The edge, when suitably sealed will be more uniform on the drum. This is made out of 20×3/4” discs of MDF.

So I cut the two boards for the table and 20 square blanks for the drum discs up. Glued up the two-layer ‘table’

and proceeded to cut central holes in all 20 of the drum blanks. Merde, nous sommes European avec un systeme metric. (google translate would be good here). My capacious metric bit set has various 18mm and 20mm bits but no 19mm bit (3/4” = 19.05mm). Then I remembered my old woodwork teacher saying “Never throw an old tool away”, in my head. After grubbing around for 15 minutes I found my old imperial bit stash at the back of a draw, complete with a 3/4” flat bit. Thank you Mr. Jenkins, right about so many of life’s mysteries, an ex-marine woodwork teacher. Set up the drill press and holed the lot in 15 minutes.

Or from the end. I present at great expense and short notice a 15” long 3/4” hole in 20 sheets of MDF.

I’ve made up a jig to cut them circular, on the bandsaw.

and now I have to pluck up the courage, fettle the bandsaw and go for it.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com



15 comments so far

View patron's profile

patron

13034 posts in 1994 days


#1 posted 05-14-2010 02:12 PM

fettle away , what !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View BritBoxmaker's profile

BritBoxmaker

4369 posts in 1689 days


#2 posted 05-14-2010 02:19 PM

lol

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View Cozmo35's profile

Cozmo35

2198 posts in 1688 days


#3 posted 05-14-2010 02:49 PM

LOL! I like it!!

-- If you don't work, you don't eat!.....Garland, TX

View Mary Anne's profile

Mary Anne

1057 posts in 1861 days


#4 posted 05-14-2010 03:01 PM

Woodworking and several language lessons all in one! And it is not even 9 o’clock in the morning.

One of my favorite stories is about when I first moved to the Deep South and I had difficulty understanding some of the accents. Then I overheard two women discussing a man from “Anglund” and he had one a’ them “ack cints.”

View stefang's profile

stefang

13019 posts in 1987 days


#5 posted 05-14-2010 03:32 PM

I used to speak Anglush Mary Anne, but now I’ve gone over to the universal language, ‘Nonsense’.

I agree with you Martyn that the mdf should do fine. It is after all what the drum is made out of, so why not the table too. If you screw on the hardboard it would be easy to replace as required. I will be interested to see if the use of a soft wood frame will make any difference (I’m not inferring here that it will). It should be ok with the lap joint construction. I hope you follow up with a review after you have used it a year or so.

-- Mike, an American living in Norway.

View spaids's profile

spaids

699 posts in 2346 days


#6 posted 05-14-2010 05:14 PM

I have been very interested in making one of these for a while. Someday I will get to it… I hope. I’m curious about how your rounding the cylinder. I see that you are going to round each “puck” on your bandsaw. After that will you assemble the sander and power up to sort of turn the cylinder smooth and perfect? I guess if you put sandpaper on the bed and raise it then the cylinder would be perfect and parallel to the bed which both are needed. Maybe your next blog will show your process.

Great blog. Thanks
Spaids

-- Wipe the blood stains from your blade before coming in.--

View BritBoxmaker's profile

BritBoxmaker

4369 posts in 1689 days


#7 posted 05-14-2010 05:18 PM

Good idea, Mike. The review that is. I hope that I’ve got all the softwood faces that need it covered in hardwood. Other than that its warping and whether the frame will take the weight of the motor that are going to be potential problems, I think.

Mary Anne. lol. Don’t know if you tried Google but it mis-translates. Merde is what you often have to scrape off your shoe, not ‘damn’.

Martyn

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View SPalm's profile

SPalm

4808 posts in 2535 days


#8 posted 05-14-2010 05:23 PM

Lookin’ good.

I suspect that a double MDF table will suffice. Formica would be nice – for slipperiness, scratch resistance, and it really does add a quite bit of torsional strength (especially if you apply it to both sides). But hey, without autofeed, I doubt you will be taking too thick of a cut. I you do, you will end up shooting boards across the room ala Dustbunny.

Steve

-- -- I'm no rocket surgeon

View BritBoxmaker's profile

BritBoxmaker

4369 posts in 1689 days


#9 posted 05-14-2010 05:40 PM

Spaids, you got it.

Steve, I’m only planning on using 150 grit on it anyway and nice gradual cuts. Its more for cleaning up after the planer (jointer) and final flat sanding on projects rather than heavy work.

Martyn

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View degoose's profile

degoose

7012 posts in 2007 days


#10 posted 05-14-2010 10:09 PM

Keep plodding along. Looking fine so far..

-- Drink twice... and don't bother to cut... @ lazylarrywoodworks.com.au For lovers of all things timber...

View BritBoxmaker's profile

BritBoxmaker

4369 posts in 1689 days


#11 posted 05-14-2010 10:28 PM

Ta mate

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View littlecope's profile

littlecope

2908 posts in 2155 days


#12 posted 05-15-2010 10:36 AM

Go, Man, Go!!!
So Martyn, have you decided whether you enjoy it here on Lumberjocks yet?? :)

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View BritBoxmaker's profile

BritBoxmaker

4369 posts in 1689 days


#13 posted 05-15-2010 11:30 AM

Mike. This is the most fun I’ve had, woodworking, in years.

Martyn

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View BarbS's profile

BarbS

2434 posts in 2738 days


#14 posted 05-15-2010 04:54 PM

5×10’ sheets of formica? Around here we can visit a cabinet shop and ask if they have any sink-cut-out throw-aways, which are countertop pieces covered in formica (usually.) You can get a pretty good size for next to nothing. Is that possible there?
And I, for one, would like to hear more references to ex-Marine Mr. Jenkins and all life’s mysteries. I wish I’d had one of those!

-- http://barbsid.blogspot.com/

View BritBoxmaker's profile

BritBoxmaker

4369 posts in 1689 days


#15 posted 05-15-2010 05:18 PM

Unfortunately, Barbs, all the little hardware and DIY shops that did this in the UK have been killed off or swallowed up by the big DIY (do it yourself) chains. Kitchen worktops are mostly sold through these. There aren’t a whole lot of cabinet makers involved in general kitchen cabinet manufacture, at least local to me, as there’s very little margin in it.

Mr. Jenkins once advised me ” Don’t get married until you’re at least 30. See a bit of life first”. I got married at 37 and saw a whole lot of life beforehand thanks to this priceless gem. I wonder where he is now I could still use his advice.

Martyn

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

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