4" disk

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Forum topic by Partridge posted 10-07-2009 12:29 AM 1234 views 0 times favorited 12 replies Add to Favorites Watch
View Partridge's profile


296 posts in 3982 days

10-07-2009 12:29 AM

I amt trying my hand at making a drum sander and Iam have trouble cutting disk with band saw jig.
1/4 blade.
3/4 sawdust board
center hole 5\8

the blade just wanders and wants to bind.
is there a better way

-- I get out in the shop when I can

12 replies so far

View mski's profile


439 posts in 4006 days

#1 posted 10-07-2009 12:54 AM

I have that trouble too, the blade’s cutting edge has to be aligned with the center pivot point of the jig,
I could never get consistent circles so I scrapped it and use my router with a home made circle jig, perfect circles with no saw marks, hope this helps.


View lew's profile


12102 posts in 3781 days

#2 posted 10-07-2009 01:26 AM

Move the jig so the leading edge of the teeth are on a line with your pivot pin. That should solve the binding problem. Somewhere I saw a chart that had a 1/4’ blade should be able to cut a 3/8” radius- that was probably the absolute smallest.

A wondering blade might mean that the tension on the band saw blade is not sufficient.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View papadan's profile


3584 posts in 3394 days

#3 posted 10-07-2009 01:31 AM

I am planning on using a 4”hole saw when I start building my drumm sander. The 1/4” pilot drill will aid in drilling the larger center hole also.

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 3312 days

#4 posted 10-07-2009 11:29 PM

I agree with papadan, except to get a 4” disc, you need a larger hole saw. The 4” is the outside diameter of the hole saw, which will be the size of the hole you cut. To get a 4” disc, you will need a 4 1/8” or maybe 4 1/4” hole saw.


View dbhost's profile


5726 posts in 3258 days

#5 posted 10-07-2009 11:46 PM

Got lathe?

-- Please like and subscribe to my YouTube Channel

View Mark's profile


1807 posts in 3300 days

#6 posted 10-08-2009 12:19 AM

im with mski…the holesaw does work but if you dont have that big of a hole saw jig up your router to cut a radius around into a full circle…makes perfect edges with no bumps to worry about or sanding to do.

-- M.K.

View Vincent Nocito's profile

Vincent Nocito

485 posts in 3390 days

#7 posted 10-08-2009 12:45 AM

Try a circle cutter with the blade turned to pruduce a flat circle instead of a wheel profile. I used this to make a laminated drum as part of a toy train many years ago. Use a drll press and slow the speed to about 250 rpm.

View Jim Crockett (USN Retired)'s profile

Jim Crockett (USN Retired)

852 posts in 3759 days

#8 posted 10-08-2009 05:04 AM

Draw the 4” disk with a compass. Using a jigsaw, cut close to the line – don’t worry if it isn’t very even. Drill a 1/4” hole in the center of the circle – use the hole made with the compass as a pilot. Insert a 1/4” bolt, with washers, and tighten down with a nut. Insert bolt end in your drill or drill press. Hold a sanding block to the edge until you have a 4” diameter circle.


-- A veteran is someone who, at one point in his/her life, wrote a blank check made payable to "The United States of America," for an amount of "up to and including his/her life".

View Partridge's profile


296 posts in 3982 days

#9 posted 10-09-2009 06:05 PM

you all have good ideas thank you…

I thought of the hole saw and circle cutter and this would do the job well. but ass i thought about next step i realized i know have a 1/4 hole in the center and i need it to be a 5/8 hole. there is only one kind of bit that i know of that will chase that hole. I do not have this bit and on pricing this out it was going to cost 20 to 30 bucks.

The lathe is and idea that i will try next. i was thinking of gluing 8” up at a time.

Jim , this system work but you have to be care full you do not oval the peace. 21 would take some time but it could be done.

-- I get out in the shop when I can

View stefang's profile


15881 posts in 3360 days

#10 posted 10-09-2009 06:15 PM

The lathe is a good idea, but it could be a little difficult getting a consistent diameter unless you are very careful and check your progress often.

-- Mike, an American living in Norway.

View davidpettinger's profile


661 posts in 3226 days

#11 posted 10-10-2009 02:57 AM

You can still rebore your hole in your 4” circles after leaving a 1/4” hole behind. Just glue a dowel in the hole, cut off flush and redore with a 5/8” spade bit. you only need enough to get the bit centered and started.

-- Methods are many,Principles are few.Methods change often,Principles never do.

View firecaster's profile


573 posts in 3444 days

#12 posted 10-10-2009 01:58 PM

If you can get them cut close to the line; after assembly put a sandpaper covered piece of plywood on your sander bed and lower the turning discs (drum) to it. Sanding them all at the same time. They will be exactly the same diameter.

-- Father of two sons. Both Eagle Scouts.

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