Crazy sander idea...

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Forum topic by JSB posted 12-07-2012 02:01 AM 1627 views 1 time favorited 20 replies Add to Favorites Watch
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737 posts in 2249 days

12-07-2012 02:01 AM

I have been wanting to make a disk sander for a while now but cant track down a decent motor. I was thinking, which also breeds danger, about using some old tools I had laying around. I happen to have 4 circular saws and only use one. What about mounting one upside down on a board, making a 90* table for it, putting a metal cutoff blade on it for rigidity, and a peel and stick sanding pad. Whatcha think? I keep telling myself its a bad idea then that little voice in the back of my head says to try it, it might just work out well. I have googled the idea a couple times and only find 10” disks for table saws. I could care less if I destroy the saw as its just collecting dust. I just dont want to make a mess out of some skin ;)

-- Jay -

20 replies so far

View Monte Pittman's profile

Monte Pittman

29953 posts in 2509 days

#1 posted 12-07-2012 02:06 AM

Part of me says it could work. Part of me says chance of injury is eminent :O

-- Nature created it, I just assemble it.

View Grandpa's profile


3261 posts in 2847 days

#2 posted 12-07-2012 02:21 AM

It is rough when you accidently bump the sanding disc with your finger. It would be extremely tough bumping a metal cutoff blade with your finger. Those things do happen. I don’t like metal or masonry blades because it they get a bump they might crack and then they tend to break apart and throw pieces all over the place. I bought a 12” disc sander from Grizzly for not much. I think it was under $200 on sale. They were probably selling out that model line and got rid of them so they could introduce the model with the face shield over the right half of the disc. Look into one of those and you won’t be sorry.

BTW, I have a friend that is a welder by trade. He had a grinding disc like you describe that came apart and flew off his air grinder. It went through the side of his welding hood and nicked part of his head. He was very fortunate.

View a1Jim's profile


117270 posts in 3748 days

#3 posted 12-07-2012 02:42 AM

Let me be blunt ,DON’T DO IT !!!!! There are two things I don’t like about it #1 the circular saw# 2 The cut-off blade.

some alternatives

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Nicholas Hall

352 posts in 2278 days

#4 posted 12-07-2012 02:54 AM

I love improvised tools as much as the next guy, and I’ve been know to choose quixotic projects over self preservation from time to time, but even I think this idea has trouble written all over it. It’s against my nature to agree with the majority, but I agree with all of the posts above. Keep all of your fingers, and with the money you’ve saved on surgery, you should pre-emptively buy yourself a disc sander :)

-- Outside of a dog, a book is a man's best friend. Inside of a dog, it's too dark to read. -Groucho Marx

View crank49's profile


4032 posts in 3142 days

#5 posted 12-07-2012 03:19 AM

I got this one at Harbor Freight for less than $100 and I love it.

It’s a 12” direct drive.

They have a 10” version but I have seen really bad reviews on it.

View Mark Shymanski's profile

Mark Shymanski

5623 posts in 3884 days

#6 posted 01-06-2013 01:26 AM

Wouldn’t the speed be too fast? Would the bearings stand up to the side loading?

-- "Checking for square? What madness is this! The cabinet is square because I will it to be so!" Jeremy Greiner LJ Topic#20953 2011 Feb 2

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3261 posts in 2847 days

#7 posted 01-06-2013 01:40 AM

get a disc and look for a cheap benchtop saw at a yard sale. the discs are sold everywhere

View JSB's profile


737 posts in 2249 days

#8 posted 01-06-2013 01:46 AM

Well it has been about a month since I posted the idea. I have pretty much abandoned the notion as I do not have health insurance ;)

I just cant see letting these saws sit aside and collect dust. What about mounting a v groove pulley to one and mounting it below a drum sander assembly?

-- Jay -

View Dusty56's profile


11822 posts in 3859 days

#9 posted 01-06-2013 01:49 AM
Keep an eye on Craigslist in your area : )
Sell your unwanted saws on Craigslist or donate them to charity.
Sounds like you can’t wait to injure yourself even though you don’t have insurance . LOL

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

View JSB's profile


737 posts in 2249 days

#10 posted 01-06-2013 01:58 AM

The purpose of this thread was to try to re-purpose some tools. I am not going to buy one. And craigslist in my area is full of $150 craftsman miter saws. Thanks for all the input :)

-- Jay -

View derosa's profile


1577 posts in 3007 days

#11 posted 01-06-2013 04:49 AM

Best I can offer on your idea, ditch the cutoff wheel and create a disc out of ply and your first time with it started up sand off the sharp edges. The cutoff wheel I think is what is frightening most people first, I have a disc sander and make my own discs due to it being an odd size and me being cheap. A couple times I haven’t gotten the paper perfectly flush to the disc and been cut by the edge of it, a cut off disc seems like a whole world of pain waiting to happen. Mine is also a 1/3hp motor going at 2500 rpms and while I can bog it down with ease I can use it to trim a 3” thick piece of oak or maple to a drawn line with no effort or even shape wood rather then cutting it. The torque and speed that a direct drive saw motor provides just seems scary next to what I have and mine will easily suck in clothing or fling a piece of wood from the upside of the disk. Makes your idea seem really frightening. Although I can understand repurposing I’d just toss them on craigslist and use the money for the HF 12” sander.
Good alternate could be using a 1750 rpm grinder with a disc attached, seen this and it worked well.

-- --Rev. Russ in NY-- A posse ad esse

View Mark Kornell's profile

Mark Kornell

1169 posts in 2702 days

#12 posted 01-06-2013 05:57 AM


When you take away the blade, a circular saw is just a small portable motor. Take the blade off, mount a pulley, and use it to drive a sanding disk. Or pretty much anything that can be driven using a pulley. And you have control over the pulley ratios, so you can run the disk at whatever speed you like. As long as you build a guard around the disk, it is no more or less safe than a commercial sander.

-- Mark Kornell, Kornell Wood Design

View sparks's profile


62 posts in 3260 days

#13 posted 01-06-2013 06:40 AM sells an attachment for 47.99 on page 89 of their catalog part number 95-430 and the different grit disc run 6.29 from 40 grit to 220. Hope this helps.

-- Sparks

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12398 posts in 2551 days

#14 posted 01-06-2013 08:55 AM

You can’t track down a washing machine motor or hvac squirrel cage fan? The problem with a circular saw is that it isn’t designed to run nonstop and they are also screaming loud.

-- Rick M,

View sprucegum's profile


324 posts in 2169 days

#15 posted 01-06-2013 11:17 AM

I also have some extra circular saws I just leave them as they are and put different blades on them for different purposes. I have my best one with a good general purpose blade, my old beater usually has a metal or masonary blade, and another with a fine tooth plywood blade mounted backwards for vinly siding.
Check with your local plumbing and heating guys blower motors from old warm air furnaces are pretty easy to come by.

-- A tube of calk and a gallon of paint will make a carpenter what he ain't

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