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Roto Zip Contour Drum Sanding Table

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Project by Tyler Moseley posted 1279 days ago 4097 views 21 times favorited 12 comments Add to Favorites Watch

Well, I saw a few people asking about this on various websites while I was looking for a way to do it so I figured I would put this up on here. Here’s the thing: I was in the middle of building a Toy Box for the kids when I needed some contour sanding. I don’t own an oscillating spindle sander and it’s not $150-$400 priority right now so I figured I would try to find an alternative. I have read a lot about people using drill presses as an alternative with mostly success and found a kit from Harbor freight for $8 with three different sander sizes that looked like they would get the job done. This may not be the most cost effective way to do this for most people, but since I happened to have an old rotozip lying around that wasn’t getting much use and I bought a variable speed router switch from HF a couple years ago that didn’t work on my router and I never took it back, it was perfect for me.

There are two great cabinet shops around here (and by great I mean they throw a lot of good stuff away!) that I scavenged some 3/4” birch ply and MDF from. The base is just 3 pieces about 15”X15” (Front Back and Center) Dadoed into two side pieces about the same size. Bottom is slightly larger piece of 1/2” birch ply. Top is 3/4” MDF. I took the standard 2 piece grout cutting attachment that attaches with 1 bolt and a rectangular nut to the quick release collar and cut the collar off right below the attachment so only the connector piece was left. Then I got a longer bolt and permanently screwed it to a piece of 1/2” ply about 1 1/2”X9” and drilled two 1/4” holes in the outer sides of the ply. I routed some matching grooves in the center piece and used some knobs from woodcraft to make it adjust about 6” or so. These were all completely imprecise measurements just thrown together and adjusted to work.

The Lid/Surface is 3/4” MDF. i used the roto zip inside the cabinet with a drill bit in it to drill a centered hole for the zero clearance cutout. then cut a 4 1/2” round hole using a hole saw with drill bit to center properly. Then I used a raised panel router but minus the ogee to cut the groove 1/4 deep and recessed about 1/2” back from the original circle. Then again, I don’t know how practical this would be for most people but I happened to have some 1/4” PE LD sign plastic from a project I did a while back that I used with a simple circle jig and just made it smaller and smaller a little bit at a time until it fit. Then I made 5 or 6 more for future use. The lid is held on with two hinges I had to shim with some HDPE I had laying around to make them work right. (I would have just gotten better hinges but I bought them while it was late and i din’t feel like going back out.) Anyway, the lid has a single screw on the opposite side of the hinges to hold it level, but still be easily accessible. I rounded off all but two edges (accident but I don’t really care) and sanded. I will probably put a nice coat of furniture wax on it and call it done, but I might round over those last two now that I’m thinking about it.

All in all took about 2 hours to build and worked swimmingly for what I needed it for. I will definitely invest in an oscillating sander later to eliminate the sanding lines but for now it works very well for shaping and the lines are pretty easy to take off by hand. The motor speed is good and the bracket holds surprisingly sturdy so after adjusting it true it works great!

-- Measure Twice, cut two, three times, plane, join, sand, coat, sand, coat, sand, coat, buff, wax, polish, brag. It's a process.





12 comments so far

View ChuckM's profile

ChuckM

496 posts in 2265 days


#1 posted 1279 days ago

Good shop solution. Thanks for sharing.

-- The time I enjoy wasting is not time wasted

View Bruce's profile

Bruce

187 posts in 2373 days


#2 posted 1279 days ago

great idea. with the quick release colar cut, will you still be able to use the rotozip seperately?

-- I think of Jack Nicholson as the Joker in Batman when he says "Where does he get those wonderful toys" and ask WHERE DO U GUYS GET ALL THAT WONDERFUL WOOD?

View Tyler Moseley's profile

Tyler Moseley

48 posts in 1384 days


#3 posted 1279 days ago

The Rotozip was not affected by cutting the accessory (which is way too flexible in my book anyway) but it does sacrifice the quick release foot that comes with it. It’s about $8 + shipping to replace if necessary.
http://www.ereplacementparts.com/depth-gauge-p-121808.html

-- Measure Twice, cut two, three times, plane, join, sand, coat, sand, coat, sand, coat, buff, wax, polish, brag. It's a process.

View docholladay's profile

docholladay

1286 posts in 1657 days


#4 posted 1279 days ago

slick idea. This gives me an idea with an ol router that I have. I never use the router because it is old and it doesn’t have the features that my newer routers have. However, it would work for this and I even have one of those speed controls that I could use. Now that I mention it, I could simply get another router table plate and mount this router to it and it would be a quick 5 minute swap to put it in my router table.

Doc

-- Hey, woodworking ain't brain surgery. Just do something and keep trying till you get it. Doc

View Dennisgrosen's profile

Dennisgrosen

10850 posts in 1713 days


#5 posted 1279 days ago

niiice little helper
thankĀ“s for sharing the idea
Dennis

View Ken90712's profile

Ken90712

14821 posts in 1787 days


#6 posted 1279 days ago

Very interesting idea. Kuddos to you! Amazing what fellow LJ’s come up with.

-- Ken, "Everyday above ground is a good day!"

View Diggerjacks's profile

Diggerjacks

1738 posts in 1737 days


#7 posted 1278 days ago

Hello

Interesting idea

What do you think about using a dust collector on your project ?

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Tyler Moseley's profile

Tyler Moseley

48 posts in 1384 days


#8 posted 1278 days ago

I just drilled a 2 1/2” hole in the back bottom (pic2) for a shop vac that works better than I thought it would actually, but you could put some kind official port on there also fairly easily.

-- Measure Twice, cut two, three times, plane, join, sand, coat, sand, coat, sand, coat, buff, wax, polish, brag. It's a process.

View Dusty56's profile

Dusty56

11638 posts in 2286 days


#9 posted 1278 days ago

Nice build …how slow can it turn before it stalls out ? (Does it have enough torque to keep spinning ?)
thanks : )

-- I'm absolutely positive that I couldn't be more uncertain!

View Tyler Moseley's profile

Tyler Moseley

48 posts in 1384 days


#10 posted 1278 days ago

The 3/4” does fine on the lowest speed, The largest drum needs to be turned up to about 1/3 power or it bogs down a little too easy.

-- Measure Twice, cut two, three times, plane, join, sand, coat, sand, coat, sand, coat, buff, wax, polish, brag. It's a process.

View Dusty56's profile

Dusty56

11638 posts in 2286 days


#11 posted 1278 days ago

Thank you : )

-- I'm absolutely positive that I couldn't be more uncertain!

View Bob817's profile

Bob817

644 posts in 981 days


#12 posted 836 days ago

That’s a great idea you got there.

-- ~ Bob ~ Newton, N.H.

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