Homemade Punch Plate for Makita BO4900V 1/2 Sheet Sander

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Blog entry by Rich posted 12-03-2016 04:59 AM 887 reads 0 times favorited 0 comments Add to Favorites Watch

I’m sold on Makita sanders. I’ve owned Porter Cable sanders going back decades. Is it that mine are old and tired, or is Makita superior? I don’ t know. I do know that these Makitas are real workhorses and the fact that even the fractional sheet models have dust collection makes them perfect for me.

I’m really impressed with the dust collection on the Makita RO sander model BO5041. I have a Jet dust collector and a shop vac, but I hate having a hose to deal with in addition to the power cord when I’m sanding large panels, like for my interior doors that I build. So, when a sander can do a decent job with just a collection bag attached, I really like it.

I wanted a 1/2 sheet sander for better flattening on large panels. The BO4900V fits the bill. But, unlike their 1/4 and 1/3 sheet sanders, it does not come with a punch plate. I have no idea why. To order one costs between $23 and $38. That’s not that much money, but before I ordered one, I wanted to try making my own. How hard can it be?

I took a 1/2 inch piece of baltic birch plywood, and used 1/4 inch MDF strips to trim the bed. I used plain old 1/4 inch dowel pins that I put in a drill and spun against 120 grit to put about a 30º shoulder on each to sharpen them. I used the sheet of punched paper that ships with the sander as a template, drilled the base and glued the pins in to make a punch plate.

Here it is:

It works great. That BO4900V sucks dust just as well as the random orbit sander. I wish it had a permanent cloth bag instead of the paper one, but it’s shown itself to be durable, and I just order five of them for about $15. Those should last me almost indefinitely.

— Rich

-- No matter how much you push the envelope, it'll still be stationery.

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