for an upcoming project i need to sand some tight inside curves and as i don't have an oscillating spindle sander i want to make some sanding spindles, that i can use in the drill press the spindles are gonna be made from birch plywood and here i'm cutting out some disks with a hole-saw i drill right to the edge, so the hole-saw overlaps the edge and can clear all the sawdust from the saw kerf
router woodworking amazon, that makes it work much better and you won't get any burn marks then i marked the disks several more times on a piece again making sure that hole-saw overlaps the edge and i mark the center with a brad point drill bit
then drilling out more disks i did exactly the same thing for some some smaller disks and also some bigger ones but it's a really bad idea to hold these small pieces by hand when drilling with a hole-saw this big so after i learned my lesson, i screwed the piece onto the backer-piece and clamped it to the table i did the same for the following disks the hole-saw always leaves some burr, so i sand that off real quick for the shafts i just want to use a bolt the only problem with these bolts is, that they are a little short i could just buy longer ones, but that would take a trip to the hardware store
so what i want to do instead is to sink the head into the bottom a little bit, so this end sticks out further the hole needs to be centered, so i use a drill bit and clamp everything down then without moving anything i switch to the forstner bit and drill the hole i also did this to the top disk a little bit to sink the nut into it and that makes for even more shaft sticking out now after i did this i noticed that i can't reach the bolt head with the wrench anymore and i was afraid that i couldn't tighten the bolt then but it turned out that the wood engages with the threads really well
and they lock it pretty nicely and i can really tighten it up and the bolt doesn't spin at all then putting it together with glue the glue is dry, next you need to turn them true the easy way to do this is to use a lathe and a three-jaw-chuck for the lathe and just mount the piece here and turn it but probably not everyone has a lathe, so i show you how to do it with the drill press. i just chucked the piece in the drill press and clamped a big block of wood here and now if you look at it at this angle
it's just like a lathe and you can use a chisel and turn it true like this. if you haven't turned anything before, you should take your time here and be very careful other than a lathe, the drill press bearings are not really made for taking up this much tangential force so if you're doing aggressive cutting here, you could damage your drillpress i'm just doing little cuts with the corner of the chisel instead of turning with a chisel, you could also use a rasp or a file to true the spindle that's the perfectly save, but very slow method, if you have to much respect from turning. after truing the disks you can sand the surface nice and even with a sanding block i put on two coats of varnish on all of them
now i can attach the sandpaper for the smallest one the easiest method would be spray adhesive, but i don't have any spray adhesive on hand so i gonna use double sided tape but i also had another idea for it with a hack-saw i cut a slot along the spindle then putting on some double sided tape one edge of the sandpaper goes inside the slot and the rest just gets wrapped around now what the slot is for one edge of the sandpaper is always inside the slot
and so the piece i'm sanding can't rip of the sandpaper by catching on that edge because it's hidden in the slot. for the other two i used the method, that i picked up in this video i drill a hole through the whole spindle and then cut a slot to that hole then again one edge goes into the slot and the sandpaper gets wrapped around, but here the second edge goes into the slot as well once you have that done approximately you remove the paper again and make the second fold cleaner when you then slide it back on the sandpaper should be pretty tight on the spindle
if not, you can adjust the second fold. the sandpaper gets locked with two screws that screw into the hole between the layers on sandpaper i really prefer this method, because you don't need any glue or double sided tape then the spindle is ready to use i guess you can imagine how this sander is used so i don't think you need explanation or big demonstration on how it's used or all the ways it can be used it just sands inside curves.
