Recently a couple of buddies on here asked where I had been lately. Well, between the sports and military and work I finally tore my knee up and needed a little maintenance. Six weeks with no weight on it left me sitting on my behind dreaming of getting back in the shop.
I have a close friend named Paul, who is an amazing machinist & welder. He is the one that taught me to weld. This allowed me to make my outdoor dining table that I have posted on here. We were talking one day about how I would like a pneumatic drum sander to get into doing some Intarsia Style of Woodworking. Well Paul is the type of person once you get the wheels turning it is a GO! LOL
He says, “Let’s build one like I have in my metal shop.” Well anytime I get chance to hang out with him and learn something new it is very exciting to me. He says I have a lot of the supplies to build this in my shop.
We started with the Arbor Housing. We first put the arbor on the CNC lathe and trued the inside of each end to a dimension of 1 5/8”. This would allow us to install two R-12 double shielded bearing one on each end. One side the bearing will be held in by the 8 inch rubber wheel that has aluminum inserts to preventing it from moving. To hold the other sides bearing, we cut a snap ring grove inside the housing. We then trued up the outside of the housing, well because it’s fun. :>)
We next cut a piece of 5/8 stock Stainless rod to size to put in the lathe. We cut both ends to .075. One end we put left handed threads on that will hold the wheel on with a 1 1/8” nut. The other end we cut a shoulder for the bearing to press against. We then cut a slot on one end of the shaft on the Bridgeport for a key to hold the pulley in place.
We inserted the two R-12 shielded bearings in the housing and inserted the snap ring on the non-threaded side of the shaft. **Note we would have used Metric bearings instead of the R-12. However, due to the thickness of the wall housing after truing it up, the R-12 was the biggest one we could insert.
Now we started the layout on the base. This was some left over aluminum roller tray used to move helicopters around. Due the inconsistencies of the housing we centered it were we thought we could get the most adjustments out of the pulleys later. We drilled and tapped these four holes to 3/8-16 for button head screws to secure the housing. Next was aligning the motor pulleys with the housing pulleys. Once we had that lined up we drill and tapped four 5/16-18 holes for the motor mount bolts. The Motor is a ½ HP GE sealed motor. We figure the math out on the speed we wanted to achieve.
(Paul taught me this),
Optimum speed is, 1750×2.5” (pulley) = 4375 rpms / 3” (pulley) = total RPM of 1458.
We temporally put things together and gave her a test run. So far so good!!! We used some Oak. It worked perfectly with no burning. Changing pulleys and speed later if needed will be a snap.
Up Next, Build and weld the housings and guard for the belt. Build and weld the brackets on the base to hold the belt guard. Build and weld the shield and dust collector attachment. Wire up the magnetic holding switch, and power cord. We already changed the motor over to CCW. We need to cut the square cut out for the switch on the base.
So what color should we make this sander? I plan on leaving the motor gray. And the diamond plate shinny. All the smooth aluminum I plan and painting.
As Always thx for reading and all comments and suggestions are welcome.
-- Ken, "Everyday above ground is a good day!"