This Instructable will show you how I built a bench-top edge-sanding jig to hold my hand-held belt sander on its side and allow me to precisely and carefully sand the edges of workpieces.
I built this because I do not have a permanent workspace to house a dedicated stationary tool (and those are expensive). Also, I already had a handheld belt sander, and quite a few belts for it.
This Instructable is broken down into the following steps:
Step 1: Goals, materials, & tools
Step 2: Build a support plate for your sander
Step 3. Tilt the support plate
Step 4: Build a base for the jig
Step 5: Build the work table
Step 6: Putting it together
Step 7: Final thoughts and possible improvements
And as always, the requisite disclaimer:
Caveat emptor. My advice is worth what you paid for it, and may be dangerous to your health and sanity. Read on at your own risk. Don't try this at home.
The first image is a stationary tool of the type whose function I needed to duplicate. The second image is what I had to work with (ok, I had some wood too).
I had read a set of instructions on Rockler's website detailing this idea, however I saw a few improvements that I could make, and needed to make some changes so that the design could be applied to my sander.
Materials are fairly simple:
~ belt sander
~ scrap plywood
~ scrap blocks of wood
~ tempered hard-board, melamine or some other slick table surface
~ screws (I used a combination of 1" and 1 1/4" coarse-thread drywall screws)
~ wood glue
~ tape measure
~ saw(s) (I used a circular saw, a table saw, and a jig saw, but you could work with just about anything)
~ appropriate personal protective equipment (eye protection, ear protection, respiratory protection)