| Project by Blake | posted 54 days ago | 1256 views | 33 times favorited | 62 comments | ![]() |
Boy, am I glad to have this done! I have been wanting a thickness sander for over a year now. I have ended up with so many small pieces of wood that I would love to use for boxes, but I had no way to dimension them. For a long time I thought about saving up and buying one, but the “cheapest” model is about $600 bucks, which seemed way too expensive for such a simple machine (it’s just a spinning drum!)
I have been in to building my own shop machinery lately. If you haven’t seen my router table, check it out too:
Anyway, here is the sander I found on the internet thanks to YorkshireStewart's blog:.

This is the design that made up my mind to just make my own. I basically copied the above sander. I really like this design because it seemed simple and just the right size for my work. Thanks a lot to all the Lumberjocks who let me bug them with questions and who gave me tons of advice on this project (you know who you are).
Here are some other Photos:









Construction:
- I started by building the frame out of plywood and biscuits. I primed it and spray painted it teal-blue.
- The table is a laminated scrap I got for free from a cabinet shop. I lined it with Beech (all the bare hardwood you see is Beech.)
- To raise and lower the table I built a simple mechanism with a piece of wood and some common hardware. At the top of the allthread there is a cap-bolt (with a round top) that pivots freely like a socket joint in another large nut that I found.
- I ordered the pillow block bearings online. The drum shaft is drill rod from the hardware store.
- I chopped up some 1/2” MDF into squares and then cut them into circles on my bandsaw with a impromptu circle-cutting jig. Then I stacked them up on the shaft with glue in between each circle and clamped them together to form the drum.
- I installed the motor, switch, pulleys, and link belt. Then I started it up and ran blocks of wood with sand paper stuck to them under the drum until it was uniform and true to the table.
- I built the dust hood out of Plexiglas and hardwood. I made cut-outs to fit over the pillow blocks and inserted a couple of rare-earth magnets to keep it down (but still easy to lift off)... see photo above.
- I covered the drum with epoxy to make it smooth enough for the self-adhesive velcro to stick to (which I ordered from Grizzly).
- I also ordered a 150 grit 3” wide roll of hook-n-loop sandpaper from Grizzly which I cut and stuck to the drum.
- I had a small rolling cabinet that was the perfect size which I am using for the base right now.
Stats: The drum has a 4” diameter and is 12 1/2” wide. It has a vertical capacity of about 4” tall for running entire small boxes through. The motor is 1 hp, 1725. The pulleys change the speed of the drum to about 2200 rpm’s.
It seemed to work perfectly on my first test piece! It runs very smooth and quietly and is dust free. And by the way, feed rollers/belts are over-rated. It is very easy to just push pieces through the sander, and the drum keeps them down flat against the table. I just use a flat push block to push the piece through.
Let me know if you have any other questions. This is a relatively simple and cheap project for such a handy shop machine.
-- Dust collectors suck.
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62 comments so far
Toolz
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135 posts in 133 days
posted 54 days ago
Good looking piece of equipment Blake. I really admire those who can make their own.
-- Growing older but not up!
teenagewoodworker
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1689 posts in 159 days
posted 54 days ago
thats great, building a drum sander is something I’ve thought about doing for a long time but haven’t got to yet. your’s came out great too. those big drum sanders do seem overpriced for what they are so its good that we can always resort to making our own. thanks for the post.
Scott Bryan
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7806 posts in 213 days
posted 54 days ago
Blake,
You did well with this. This is a tool that will be very useful in your shop. I would love to have one of these but, like you am put off by the price tag. I may have to look into building one of these as well.
Thanks for the post.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
Steffen
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229 posts in 426 days
posted 54 days ago
Can you come to my house and build one? That thing is great! I had looked at one on line someone had built before and wondered about building one myself. I make shaker boxes and it certainly would be handy. Nice job Blake.
-- Steffen
Dominic Vanacora
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309 posts in 260 days
posted 54 days ago
A drum sander this size would cost with shipping a little over $1100.00. I really don’t care what yours cost. You manufactured it from a drawing or an idea and its just the way you wanted it. Perfect. WoW what a undertaking. Your the Man!
-- Dominic, Trinity, Florida
Joey
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150 posts in 206 days
posted 54 days ago
that is cool. I want one so i can start cutting my own veneers. this would be perfect.
-- Joey, Magee, Ms http://woodnwaresms.com
Rob
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69 posts in 58 days
posted 54 days ago
Very impressive. Building stuff is one thing, but building your own power tool is DIY-extreme! Nice job.
gizmodyne
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1410 posts in 481 days
posted 54 days ago
Excellent Blake! I want to make one now. Question: Does only one side of the table elevate?
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
TomK
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337 posts in 265 days
posted 54 days ago
This is great. I just favorited it!
-- North Texas
Scott
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52 posts in 252 days
posted 54 days ago
You have done a wonderful job building this sander. The only thing i would recommend is that you build a guard to cover the drive belt.
-- Scott, Kentucky ----- "Let us so live that when we come to die even the undertaker will be sorry" Mark Twain
Chris
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913 posts in 382 days
posted 54 days ago
Well Done Blake…. Now all we need are the detailed step-by-step plans. :)
-- Chris
Blake
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1811 posts in 265 days
posted 54 days ago
Gizmodyne: Yes, the table is hinged in the back.
Scott: I thought about it but it is relatively out of the way, and I am the only one that will use this machine. But I might do this in the future, thanks.
-- Dust collectors suck.
GaryK
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8183 posts in 379 days
posted 54 days ago
Great job Blake! I know what you mean about it being easy to push through by hand. My first thickness sander
was only 3” wide! I won’t give my feed system though.
Again, Great job!
-- Gary, East TX -- The longest journey begins with a single step.
pashley
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196 posts in 108 days
posted 54 days ago
Great. Yet ANOTHER project I’m going to have to “get to”! LOL!
-- -Be Blessed!, Patrick
Tony Z
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109 posts in 181 days
posted 54 days ago
That is awesome. I will be contacting you when I build mine some day. How much time did you have into it. Time is one thing I’m short of these days.
-- Tony, Ohio
Dusty56
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553 posts in 79 days
posted 54 days ago
I wish that I had seen this before I wasted $1000 on my junk Delta drum sander….I’ve spent more time trying to get it to sand evenly across the width of the drum and the rest of the machine regarding the height adjustment is built so cheaply that it always binds up ….never again will I buy anything made by Delta !!!
-- Dusty56@comcast.net
Woodhacker
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327 posts in 114 days
posted 54 days ago
Really cool Blake! As someone who enjoys making boxes, I could really put one of these to good use.
(Great photos by the way.)
-- Martin, Kansas
dlcarver
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227 posts in 121 days
posted 54 days ago
Blake, this is fantastic !!!! I love it when people make do with what they have…. you have very little invested. I have also invented many jigs and tools to do the jobs I need them for…. even if it’s a one timer.
Great job !!!
Dave
-- Dave Leitem,Butler,Pa.,http://dlcarver.etsy.com
trifern
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1920 posts in 158 days
posted 54 days ago
Totally awesome. Thanks for sharing.
-- Depend on the rabbit's foot if you will, but remember it didn't work for the rabbit.
gizmodyne
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1410 posts in 481 days
posted 54 days ago
Future Lumberjocks Challenge? Build a drum sander!
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
DAN
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2584 posts in 374 days
posted 54 days ago
good one !
-- a legend in my own mind ...
Todd A. Clippinger
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2450 posts in 490 days
posted 54 days ago
I am excited to finally see this project!
The sander will definitely change the way that you work and what you are able to work.
Looks like a great job.
-- Todd A. Clippinger, Montana, http://amcraftsman.com
Douglas Bordner
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2261 posts in 455 days
posted 54 days ago
Looks like you have staked out a new line of teal blue tools. Excellent post and project. I jumped on the Jet/Performax 10-20, and will never look back, but I’m excited for you to have a drum sander. Just the ticket for dimensioning box assemblies, and you can pocket the difference between that big ticket purchase and the outlay for your the new Blakeline Drum Sander.
-- "Bordnerizing" perfectly good lumber for over a decade.
Mathew Nedeljko
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33 posts in 221 days
posted 54 days ago
Blake, that is one of the best DIY drum sanders I have seen. I looked at quite a few before I bit the bullet and shelled out the dough for a Performax 16-32 machine a couple of years ago. Once the money was spent I never regretted it as it has saved me so much time. I use it on every project I do. I’m sure you will too.
Just one thing to watch out for. Given that you did not add a power feed system, make sure that you feed your stock through the machine at a constant speed. Any momentary stop or bump will cause the machine to create a “snipe” line across the entire width of your board. It can be sanded out with a second pass or with an ROS later but it is still a pain.
Happy Sanding!
-- When your work speaks for itself, don't interrupt! Henry J. Kaiser
Praki
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66 posts in 388 days
posted 54 days ago
This is very cool! A drum sander is on my list of tings to make for myself and I think I have found which plan to copy ;)
-- Praki, Aspiring Woodworker
USCJeff
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754 posts in 459 days
posted 54 days ago
If you don’t mind me asking, what do you estimate your investment was for this? I have a Shopnotes plan for a Tablesaw powered Sander I’ve been thinking about. They did it for under $300. $200 I believe. I’m with you, I can’t quite make the leap to the $700+ just yet. Couple other big essentials to buy before a time saver. Well done. Will have to favorite for down the road. Blake, you’ve kept adding some cool things to the site. Keep em coming.
-- Jeff, South Carolina
Tony
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520 posts in 421 days
posted 54 days ago
Very nice project, well executed. I’ve been thinking about mine for 2 years now and I still have not started, you have put me to shame for the quick turn around.
-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)
Blake
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1811 posts in 265 days
posted 54 days ago
Thanks, everyone.
As far as cost…
In other words, it is possible to build this sander for about $50 to $100 bucks.
-- Dust collectors suck.
SteveKorz
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616 posts in 105 days
posted 54 days ago
That’s it, I’m gonna have to make one of those. You’ve done a fine job on this one… Thanks Blake for the post!
—Steve
-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17)
Jiri Parkman
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531 posts in 203 days
posted 54 days ago
One word only. That is amazing. Thanks for this post. And congratulations.
-- Jiri
moshel
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54 posts in 74 days
posted 53 days ago
amazing job. i loved the rare earth magnets. well, actually i loved everything…
-- The woods are lovely, dark and deep, but I have promises to keep...
TedM
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565 posts in 123 days
posted 53 days ago
Cool! Ingenuity at it’s best!
-- I'm a wood magician... I can turn fine lumber into firewood before your very eyes! - http://www.woodworkersguide.com
YooperCasey
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58 posts in 224 days
posted 53 days ago
Looks great Blake. Simple and effective is the best way, you engineered it well! Nice touch with the magnets too!
-- Casey, Engineer, Escanaba, MI
Russel
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1027 posts in 330 days
posted 53 days ago
Downright impressive Blake. You make it look simple. This one statement of yours, ”I started it up and ran blocks of wood with sand paper stuck to them under the drum until it was uniform and true to the table.” said lot about your attention to detail. This simple and effective technique had me saying, “I would’ve never thought of that.” Very well done.
-- If at first you don't succeed, try again. Then quit. No use being a darn fool about it.
Dadoo
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1398 posts in 381 days
posted 53 days ago
Excellent job Blake! I like your ideas on getting the drum round too! Very inventive.
So you’re using 150 grit paper but would it also be feasable to make another drum…one covered with 80 grit for thickness work?
-- Bob Vila would be so proud of you!
SPalm
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658 posts in 273 days
posted 53 days ago
Excellent job. (as always from you). I just love shop made machines. I bet you will use it alot.
-- Stevethepeeve -- I'm no rocket surgeon
Billp
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195 posts in 591 days
posted 53 days ago
Right on Blake you da man!
-- Billp
ratchet
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68 posts in 178 days
posted 53 days ago
Blake; You are my new toolmaking hero. Your drum sanding creation appears to be of better than commercial quality. Your “scrounge-itudinal” prowess is truly commendable.
Nice work bro.
Another favorite for me.
+1 on the request for a parts list, plans, and procedures.
Jeff
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941 posts in 485 days
posted 53 days ago
I’m teal blue with tool envy. Man, this is really slick Blake!! Thanks for the post and well written explaination.
-- Jeff, St. Paul, MN
spaids
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48 posts in 84 days
posted 53 days ago
Blake you forgot a bullet point on your cost list.
. Making a $600 tool for $50… Priceless
I have a quesiton though. I am a little confused on how it works if the table does not have a belt on it. Keep in mind as you answer this question that my signature is not a lie.
I’m gonna have to put you in my buddy list for this post.
-- Total Freakin Newbie
CharlieM1958
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3538 posts in 609 days
posted 53 days ago
Blake, this is fantastic! I could really use one of these, but, like you, the price has always put me off. Looks like I’ve got no excuse not to follow your lead.
-- Charlie M. "Woodworking - patience = firewood"
HokieMojo
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162 posts in 119 days
posted 53 days ago
I really like this project. I’m jsut wondering how the dust collection can work. Wouldn’t the dust colelctor need to be pretty powerful to pull the dust all the way from the other side of the drum? As you can see, this question is coming from someone that still uses a shop-vac.
Damian Penney
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592 posts in 382 days
posted 53 days ago
This came out really nicely :) Really nicely put together and I like the use of the magnets. Enjoy!
-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso
John Gray
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479 posts in 276 days
posted 53 days ago
SUPER!!!!! I favourited it.
-- Only the Shadow knows....................
Andy
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296 posts in 299 days
posted 53 days ago
Thanks for posting this Blake.I have been wanting one of these too,but couldnt justify the cost.You have convinced me to build one too,thanks for the nudge.
-- " Stubborn tenacity substitutes for natural ability" ANDY
Texasgaloot
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182 posts in 91 days
posted 53 days ago
I just got the commission to build an outdoor bar out of a 6’x19”x4” slab of pecan. I was thinking my best approach would be to make sure my Stanley No.-8 was ScarySharp, but it has two rather intimidating knots in the middle of it. A tool like this is far and away the most cost effective answer, and just made the project seem a whole lot smaller for me!! So, you are inspiring us. Thank you.
Question: have you experienced any snipe through hesitating as you feed?
-- There's no tool like an old tool...
Blake
home | projects | blog
1811 posts in 265 days
posted 53 days ago
Dadoo: ”would it also be feasable to make another drum…one covered with 80 grit” …The sandpaper is attached to the drum with hook-n-loop (velcro) so it is very easy to change to any grit. A 150’ roll costs about $30 bucks so I have only invested in one grit so far. But when I collect a variety it only takes about 30 seconds to peel one grit off and replace it with another.
Spaids: ”I am a little confused on how it works if the table does not have a belt on it” …You just push your stock through by hand or with a flat push block. It’s very easy. As Mathew Nedeljko pointed out above though, you just need to keep a consistent feed rate if you push it through manually to avoid “snipe.” (Thanks, Mathew)
HokieMojo: ”I’m jsut wondering how the dust collection can work.” …My only dust collection is also a SHOPVAC. And it works great! It sucks the dust right up into the hood. And the fact that it is totally clear makes it easy to see the dust going right up into the port. In fact, I was worried that I would have to make some kind of hanging rubber curtain in front and back of the dust port that would reach the table and create more suction. But after the test run I have decided it is not necessary.
Texasgaloot: ”have you experienced any snipe through hesitating as you feed?” …Not on the test pieces yet. Most of my work is pretty small and manageable. For something large like that it would be tough to feed it consistently. I will have to be careful.
Thanks for the comments!
-- Dust collectors suck.
gator9t9
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278 posts in 95 days
posted 53 days ago
Very nice yes …..Great job …..
A very good use of leftovers and scraps and getting your moneys worth out of all your leftovers …And you are very fortunate to have lumber yard scraps available to you …as most Home Depots will not let anyone go foraging thru their scrap pile.. and finding a feed table for zero is a very nice find …
I used a Jet Drum Sander the other day and was so surprised and amazed at how great a help and assistance they are to just about any job needing sanding .or .thicknessing
and in looking at your design of the unit
seems the most critical part of your Drum Sander build would be the setup to raise and lower ????
I would love a drum sander that is for sure ….
thanks …again great job Blake …
-- Mike in Bonney Lake " If you are real real real good your whole life, You 'll be buried in a curly maple coffin when you die."
Blake
home | projects | blog
1811 posts in 265 days
posted 53 days ago
By the way, one great resource I found online is the PDF Owners Manual, Parts List, and Specifications Sheet on “Grizzly’s 12 sander. In fact, you can order parts right from their website! This is where I got the velcro wrap for my drum as well has the hook-n-loop sandpaper rolls. But this is also where I found tons of valuable information on drum size, motor speed, etc.
-- Dust collectors suck.
dennis mitchell
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2802 posts in 705 days
posted 53 days ago
Shucks Blake! How can you top this one…home made CNC?
-- http://www.woodsongsfurniture.com
bake
home | projects | blog
10 posts in 68 days
posted 53 days ago
nice!
-- The only thing wrong with instant gratification is that it's not fast enough.
YorkshireStewart
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571 posts in 292 days
posted 52 days ago
Beautifully done Blake! I still get enormous pleasure every time I use mine. (You know you’re a Lumberjock when you get…..)
Wish I had a bright red drive belt though! :>)
Thanks for the mention.

-- Res severa verum gaudium - True pleasure is a serious business.
nat42
home | projects | blog
14 posts in 104 days
posted 50 days ago
Blake
A real great job
I have been trying to make one but my biggest problem was the drum but I think you solved that for me. The table you say is hinged How? and is it ajustable?
Great work
-- Nathan South Afirica
Blake
home | projects | blog
1811 posts in 265 days
posted 50 days ago
The table is simply attached with a piano hinge on the back and has a knob and long threaded shaft for raising and lowing the front of the table (see the photo).
-- Dust collectors suck.
clieb91
home | projects | blog
276 posts in 326 days
posted 50 days ago
Blake, Sorry I did not look at this posting sooner. The unit came out looking great and sounds like it works real good. I will be adding this to my favorites as well, certainly a project I have on my to do list.
Thanks for all the information.
CtL
-- Chris L. "Don't Dream it, Be it."
Dorje
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1695 posts in 388 days
posted 50 days ago
Super!
-- Dorje (pronounced "door-jay"), Seattle, WA
jude
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129 posts in 340 days
posted 49 days ago
that’s awesome. you’re really talented!
-- life can always be weaved into a song.
David
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80 posts in 106 days
posted 49 days ago
SWEET!!! Well thought out, well built and you did it yourself. Be proud… I’m envious. Hummmm Grizzly is right up the street from me in Bellingham; guess I best get my buns in gear.
Maybe I missed it but what about the leading edge of the sandpaper? Does it catch? Does it tuck in somewhere? can you enlighten me on that please. Thanks
David
Blake
home | projects | blog
1811 posts in 265 days
posted 49 days ago
I thought I would have a problem with that but so far so good. I may modify it if it starts to catch. The drum extends 1/4” past the table on both sides. The table has runners that stick up on each edge to keep the stock between the sides. So it is actually impossible for the edge of the sandpaper to touch the stock and the hook-n-loop seems to be holding it down ok.
-- Dust collectors suck.
woodup
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105 posts in 334 days
posted 45 days ago
Just got to say, “Wow!”. I’m very impressed.
-- Michael, Fort Worth, TX. "I wood if I could!"
PaBull
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57 posts in 56 days
posted 31 days ago
very nice, need to have one.
Californians do nice work!
-- Mark 6:3 Is not this the carpenter, the son of Mary ...
lew
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457 posts in 146 days
posted 31 days ago
Dang,
Guess what just went to #1 on my ToDo List!!
Thanks!!!!!!!
Lew