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Lathe's Disc Sander Dust Extraction

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Project by LittleBlackDuck posted 07-17-2018 04:20 AM 1398 views 5 times favorited 24 comments Add to Favorites Watch

G’day Boys and Girls.

This is a follow up of my Lathe disk sander with micro adjustment... Take 2. regarding the threat of dust collection.
After making my 320mm disc, I remembered the mess that the 230mm disc made.
Even before mounting a sanding pad to the starter (I believe that’s what the hook part is called) it was up to the office… a top up of red… and started to design a dust collector in SketchUp. After much brain-storming I finally came up with a design that I was prepared to attempt to manufacture,

Peek-a-boo

As per a lot of my past projects, I chose to laser cut the parts out of 6mm MDF and where I needed bulk I used my tried and tested lamination principle.
Pieces (ribs) glued together.

I came up with what I thought was a clever idea for attaching dust extraction. Problem was the designer didn’t write any assembly instructions so I managed to screw it up… I assembled the front 2 pieces in reverse … the top nothes on the side should have been on the LHS,

Not to admit defeat, I cut some duplicate pieces and re-laminated. I cannot say I do not learn from past experience… I did learn and repeated the same exact assembly screw up

More cutting and assembly and while the orientation was correct, the lamination alignment wasn’t…


normally I use alignment dowels, however, this time I tried a new method… clamps with clamping squares,

with mixed results… (back to alignment dowels on next project).

Fortunately the laser never sleeps so it was ready to make another production run.
Finally got it together, properly aligned and oriented, only to find I forgot to turn X-Ray on in SketchUp and when I tried to attach the extraction port to the cover bottom half, some parts overlapped… Laser wake up! Modified, cut and laminated…

quickly running out of glue.
Then it hit me…all those casks of vino… just kidding… the extraction port was spec’d on a hard to find shop-vac hose and if I needed to use another hose I’d be screwed. Came up with a new modification so that a different diameter shop-vac could be fabricated and easily attached using these 2 (currently not in action) bolts,

yeah, more cutting, laminating and glue purchasing.
While I never got around to cutting the pieces, here is a mock-up of what might need to be made using laminated MDF… the pink part is the same component as the red on the left while the green parts are what would be glued onto the pink to accept the different diameter hose…

Alternatively I could 3D print a new coupler… the blue part that fits directly in the original port and designed such that the hose (grey) fits either inside or outside the coupler…

here it’s configured for an outside fit.

The base was designed to be mounted to the lathe bed using mag switches,

The body of the collector was designed in two halves so that when the top half was removed I could easily thread the disc onto the spindle.
The bottom ribs and backing were laminated

The same procedure repeated with the top half

Then it dawned on me that the extractor port was up far too high (90°) rather than closer to the bottom. The lathe bed prevented bottom placement so I compromised at 45°.
While I had to recut the bottom pieces, as they each had a tab to locate in the base, the top pieces remained the same… though I believe I had to manually drill a ¼” bolt hole (has been modified in SU).
The base, bottom half and extractor port were glued together,

Now let’s assemble it on the lathe.

Bottom half attached by the base using mag switches on the lathe bed,

The disc threaded on,

Base and bottom half brought forward to touch the back of the disc,

Attached the top half,

Added the bottom front cover and the top collar,

Added the hardware… used slip nuts to minimise threading,

Used a 1/16” shim to set the clearance between the disc face and the front bottom cover,

Locked in final position using the mag switches and ready for use,

Don’t forget the dusty,

Close up,

All that’s left is to mount the milling table… AND… don’t forget to read the lathe’s instruction manual so you’ll know how to operate it.
For those averse to reading (like me) I have created a video so you don’t have to read the above drivel… Unfortunately I hate waste and as I was too lazy to bring my scrap bin up into the office none of the lengthy video finished up on the cutting floor.

PS. In one of the video’s close ups I noticed a bit of flaky skin around the ear… So did SWMBO… I spent the rest of the day running away from the missus and her dust busterrun away… run away!

-- If your first cut is too short... Take the second cut from the longer end... LBD





24 comments so far

View Dutchy's profile

Dutchy

3083 posts in 2315 days


#1 posted 07-17-2018 07:26 AM

Would it not have been better to buy a new sanding disk? Despite this note I have to admit that you have made a impressive sanding disk on your lathe. Take care with your fingers.

-- https://dutchypatterns.com/

View Chrisprols's profile

Chrisprols

8 posts in 1160 days


#2 posted 07-17-2018 09:29 AM

those projects merging woodworking, laser cutting, 3D printing and commercial parts (screws/nuts) are really interesting ! ... and using 3D modeling for that matter.
very creative :)

View mikeacg's profile

mikeacg

675 posts in 1204 days


#3 posted 07-17-2018 09:56 AM

Duck,

Very interesting idea! I don’t have decent dust collection in my current shop – a problem I hope to remedy at the new place. This inspires me to consider creating my own collection fixtures (some of my machines I don’t think they even make stuff like that for…). Thanks for sharing!

-- Mike, A Yooper with a drawl, http://www.artcentergraphics.com

View LittleBlackDuck's profile

LittleBlackDuck

2002 posts in 967 days


#4 posted 07-17-2018 10:37 AM

Dutchy, My disc sander has only one speed and it’s tabletop has limited maneuverability. The disc revs at 1700RPM,

it also has an aluminium table so I can’t even use my mag-switches on it.

I like the thought of variable speed control of my lathe (down to 100) and with the milling table I have the option of micro adjustment. I am clumsy freehand… it was after sanding my fingertips on the disc sander that I moved over to the slower more controllable lathe.

Here in Australia, discs by themselves (without motors) are not available (at least I don’t know where to buy). The 9” disc would probably have served me OK (instead of the new 12”, but I always want BIGGER!.

Having the sanding disc on the lathe, I had to work on an efficient dust collection.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View Dutchy's profile

Dutchy

3083 posts in 2315 days


#5 posted 07-17-2018 11:34 AM

You will love the low speed!

-- https://dutchypatterns.com/

View helluvawreck's profile

helluvawreck

32083 posts in 3013 days


#6 posted 07-17-2018 11:55 AM

This is a great addition to your lathe. It’s a fine shop made accessory and will pay off in dividends. You did a nice job on the engineering of this project and it has some outstanding features.

-- helluvawreck aka Charles, http://woodworkingexpo.wordpress.com

View Underdog's profile

Underdog

1189 posts in 2182 days


#7 posted 07-17-2018 01:40 PM

That’s pretty cool. Having a laser is a nice addition when it comes to making precision parts.

-- Jim, Georgia, USA

View LittleBlackDuck's profile

LittleBlackDuck

2002 posts in 967 days


#8 posted 07-17-2018 03:35 PM


That s pretty cool. Having a laser is a nice addition when it comes to making precision parts.

- Underdog


Must admit that making these type of jigs was the last thing on my mind when I acquired the laser… However anything that I have done on my laser could be duplicated on a CNC… and they are becoming more and more popular in the workshop.

PS. Thanks all for your kind comments…

-- If your first cut is too short... Take the second cut from the longer end... LBD

View splintergroup's profile

splintergroup

2305 posts in 1369 days


#9 posted 07-17-2018 04:51 PM

Got a good chuckle out of making the same wrong part twice! Can’t count how many times I’ve done that 8^)

View bushmaster's profile

bushmaster

3234 posts in 2429 days


#10 posted 07-17-2018 05:41 PM

Nice build, friend of mine is setting up a small shop with a wood lathe, wil have to show him this one. an incredible wack of pictures, thanks.

-- Brian - Hazelton, British Columbia

View mikeacg's profile

mikeacg

675 posts in 1204 days


#11 posted 07-17-2018 09:14 PM

Duck,

I have a laser and a couple CNCs. I bought a big stack of plexi cutoffs on Ebay a few years back and now I make jigs and all kinds of stuff out of it. These are thread racks for my embroidery shop to hold threads, in rows by color number to match the thread chart from the manufacturer (makes life pretty simple!!!)

And the laser is king when it comes to photographs!!

A CNC can’t come close to that definition! But it blows the laser away on 3D carving!!!

-- Mike, A Yooper with a drawl, http://www.artcentergraphics.com

View LittleBlackDuck's profile

LittleBlackDuck

2002 posts in 967 days


#12 posted 07-17-2018 10:00 PM



Got a good chuckle out of making the same wrong part twice! Can t count how many times I ve done that 8^)

- splintergroup


Thanks splint’up, Mum always told me that if I do something well it’s always worth an encore… unfortunately she never mentioned stuff ups.

..... setting up a small shop with a wood lathe,.....

- bushmaster


The lathe is renowned for making a mess… even worse if I use a chisel with it. I’ll try anything to minimise post operational clean up. I have always been dust collection conscious… not necessarily because of health but rather cleaning up laziness.


You will love the low speed!

- Dutchy


Already love it… Will appreciate the speed even more if I turn it on!


..... And the laser is king when it comes to photographs!!.....

..... A CNC can t come close to that definition! But it blows the laser away on 3D carving!!!

- mikeacg


I got my laser with the intention of setting up my daughter in a business… Her eagerness waned very quickly and I was stuck with the laser. I never mastered photo engraving though I would love to go down that path… I’m hear I have to read to learn… and I haven’t read the books that tells me so!
Nice zebras!

It is incredible, the job a laser does on plexi-glass… I have made quite a few jigs out of it for a woodworking teacher friend of mine for his students.

Agree with the CNC… that’s why I laser cut and laminate… to get dimension.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View mikeacg's profile

mikeacg

675 posts in 1204 days


#13 posted 07-17-2018 10:17 PM

Duck,

I will help you with photo engraving any way I can! It is a small payment for the mirth you bring to your posts!!!

A laser on glass? I do stained glass with panels that have engraved images. You will want to do this!!!

-- Mike, A Yooper with a drawl, http://www.artcentergraphics.com

View LittleBlackDuck's profile

LittleBlackDuck

2002 posts in 967 days


#14 posted 07-18-2018 02:48 AM


I will help you with photo engraving any way I can…

- mikeacg


Thanks for the offer mikea’. Unfortunatelly most learning needs reading and as people are starting to learn, the literary arts are one of my intimate nemesises…
However, as the old adage goes…
You can lead a duck to the library, but you can’t make him pick out a book!
Nevertheless, if you can point me in the right direction, I might be able to program “Dragon Naturally Speaking” software to read it to me in bed…. subliminaly I might actually remember something without waking up in a puddle.

.... A laser on glass?.....

When I first got my laser, I did try to engrave some different friends’ names on beer glasses. Unfortunately after a few drinks I insisted they all had my name on it and were MINE… hands off!.

Will look forward to some of your posts using laser… The jury is out when it comes to laser (and according to the purists even CNC) work and woodworking, however, the Blogs forum is open slather and if you toss in a bit of timber, you probably could sneak a few in under Projects forum.

PS. I take nothing away from the traditionalist woodworkers, however, I am a baby boomer that wears a millenium disguise during my library visits.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View woodbutcherbynight's profile

woodbutcherbynight

5559 posts in 2555 days


#15 posted 07-18-2018 03:20 AM

Had to go out and yet again reinvent the wheel???

LOL

Nice work, great idea, very creative!!!

-- Live to tell the stories, they sound better that way.

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