How to Make a Disk Sander

Building the Sander

• 1

  Measure a circle that’s 6 inches in diameter on the plywood, using the compass and noting the central point of the circle.

• 2

  Cut out the circle of plywood with a jigsaw and sand the edges smooth with sandpaper.

• 3

  Drill a hole all the way through the center of the circle, using a 1/4-inch countersink bit.

• 4

  Push the screw bolt through the hole, forcing it if need be; when all the way in the hole, the top of the bolt should be flush with the wood. Remove the bolt and re-drill the hole of it’s not flush.

• 5

  Fit the bolt in place and screw the nut on the other end. Tighten down by hand as far as you can. Fit and lock a pair of vise grips over the nut. Stand the disk on edge and grasp the vise grips in one hand.

• 6

  Slot the tip of a screwdriver into the screw end of the blot and tighten, keeping a firm hold on the vise grips to tighten down the bolt. Continue to tighten until the bolt is fully secure.

Fitting the Sander

• 7

  Loosen the jaws of the drill with a chuck key and fit the end of the disk spindle in place before tightening the jaws again. Check the stability of the disk; it shouldn’t move backward or forward or wobble at all. Run the drill to check that the disk moves smoothly.

• 8

  Attach a 6-inch circle of self-stick sandpaper to the front of the disk and press down to keep it in place. Run the sander for a moment to ensure the sandpaper stays in place.

• 9

  Start the sander at a low speed and bring the disk down on a piece of wood to be sanded. Replace the sandpaper when needed by peeling the circle off the plywood disk and putting another in place.