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Dave's Wide Drum Sander Build.

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Blog series by dbhost updated 05-29-2012 07:23 PM 12 parts 26378 reads 50 comments total

Part 1: Working on the design, getting the parts.

01-25-2012 08:48 PM by dbhost | 12 comments »

After seeing the many well thought out, and expertly crafted wide drum sander builds here, and on the other forums, I am sufficiently inspired and motivated to build my own. I have been working out the design, and have come to the conclusions that while the design isn’t finalized, I AM confident enough to start gathering the “Stuff” to start building it… This “Stuff” so far is… #1. Pair of 5/8” center hole cast iron ball bearing pillow blo...

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Part 2: The bearings are in, off to the machine shop...

01-28-2012 10:20 PM by dbhost | 7 comments »

The VXB 5/8” shaft pillow block bearings are in, and upon unpacking them, I made a bad discovery, the bearings are in the pillow blocks, but they are very poorly pressed in, meaning they are pressed in at a funny angle, not square to the faces. Since the safety / emissions inspection on my Saturn is expired, and I need to go to the shop for that anyway, I figure I could possibly impose upon the mechanic to use his shop press to drive these things home properly while I am there, w...

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Part 3: Sources for the parts.

01-31-2012 12:11 AM by dbhost | 5 comments »

I have been drilled as it were for the sources on the parts I am using for my drum sander. So here goes… The pillow block bearings were chosen partially due to the available axle. More on that later. I selected 5/8” pillow blocks from Amazon. Price was good, but after shipping came out to $22.45 delivered. The steel rod I have is something I have had for a VERY long time. When I was in college, I worked in a hardware store that closed down. The owner tossed a bunch of junk t...

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Part 4: The drum build. Closing in on decision time!

01-31-2012 07:28 PM by dbhost | 6 comments »

As you know from my earlier posts, I have been teetering between using a wood plugged / PVC pipe based drum, or an all wood, laminated drum… The 2 options have pros and cons to consider. PVC based drum would have the potential of suffering distortion damage due to sanding heat. However those that have done this already haven’t seen such a problem. Likewise PVC due to the lower weight would have less inertia to help with actually doing the work. Again I don’t think that...

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Part 5: Digging through the lumber racks to fish out the 2x6 stock...

02-02-2012 07:45 PM by dbhost | 2 comments »

I had previously mentioned that I was planning on using 2×6 stock, that I will S4S, cut to length matching the width left after jointing and ripping (I expect 5.25”, gluing it all up, finding center, drawing my rough circle on with a compass, and cutting to ROUGH round dimension on the band saw. With all of the issues at hand and known as discussed in my prior blog entry, I have opted to go with the wood plugged PVC drum out of a need to make the build simpler based on the tools...

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Part 6: Lousy weekend, not much to update...

02-06-2012 05:37 PM by dbhost | 2 comments »

Was sick all weekend. Stupid cold. I know some folks are following this blog series, so I just wanted to let y’all know I haven’t forgotten to post, just no real progress to report…

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Part 7: Excuse to order a new tool...

02-20-2012 02:10 AM by dbhost | 5 comments »

Since I am turning the caps for the new drum, I will need 5/8” holes centered in these caps so that the drum runs true. While it’s possible to to center bore these on the drill press, I figure it would be a whole lot easier with a Jacobs type chuck. Only one little problem… I don’t own one, yet… I’ve been eyeballing the simple “1/2 MT2 Mini-Lathe Drill Chuck from Harbor Freight Tools, item #42340. Now mind you, I paid more than if I would hav...

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Part 8: Progress on the drum.

02-21-2012 12:08 AM by dbhost | 3 comments »

Not pretty yet, and this certainly shows my extreme lack of turning skills. I have the larger of the two outer plugs round, and have it with the groove for the pulley cut in… The pulley end large side is 5.25” dia, the inside diameter is 4.75”. I am not sure I left enough thickness on the side to prevent a blowout, but I guess we will see… The first pic is the blanks glued up and the corners clipped off to keep from beating too much with the rougher… ...

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Part 9: I slowed myself down, the hard way...

02-22-2012 04:46 PM by dbhost | 3 comments »

So I spent some quality time yesterday in the shop, turning the end caps. Specifically turning the first one to final size and then cutting the shoulder into it for a nice, snug fit on the Schedule 40, and then starting to rough in the second one… I may have to redo the first as I did something stupid. I removed it from the chuck before the drill chuck came in, so I haven’t center bored it yet… I will make certain it’s good and round before I start punching that cen...

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Part 10: Progress, and congress...

02-25-2012 11:36 PM by dbhost | 0 comments »

If con is the opposite of pro, congress MUST be the opposite of progress right? The cap ends are done, which is the progress. The pulley side is actually looking really good, with a nice snug bore hole straight through the middle courtesy of the new to me drill chuck from Harbor Freight… The non pulley end I can’t seem to get rechucked so that it turns true in order to put a true straight hole through the middle, so it’s back to the lumber pile, and I just am not feeli...

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Part 11: Off to the machine shop... And the scrap bin.

05-23-2012 03:19 PM by dbhost | 0 comments »

So my pulleys came in last night, and they both are keyed. I installed the pulley onto the shaft for the motor, no biggie. Just had to tap it into place with the rubber mallet. The drum end pulley also has a keyway, but the smooth rod doesn’t. That bothers me, a LOT… I know it shouldn’t, but I am going so painstakingly carefully through this build that even that small detail is REALLY getting on my nerves… So a few calls made in my area to machine shops. I was actua...

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Part 12: Missed out on the machine shop, so far...

05-29-2012 07:23 PM by dbhost | 5 comments »

Okay, I should have gone to the machine shop on Friday, but I got more than a little busy, and they were busy on Monday, so…. What little bit of shop, or shop related time I could come up with, I glued up the blanks for the end blocks, okay actually this one will likely be a center block. I’ve got more digging to do in the scrap pile… I was able to locate the link belt, and get everything connected / test fitted over the weekend. Once the drive pulley was installed, al...

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