Angle Grinder As a Disk Sander

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Introduction: Angle Grinder As a Disk Sander

I had a need to adapt and use my Harbor Freight angle grinder as a benchtop disk sander, so I bought a 5" (127 mm) backing pad for about $10 and put together a simple build, complete with slotted table and miter gauge to produce an inexpensive benchtop tool.

Step 1: Prep the Pad

Using the same technique of making my own sanding disks as shown in my Instructable "Renewing Sanding Disks", I modified one slightly by punching a 3/4" (19.05 mm) diameter arbor hole and cutting relief slits so the retainer nut would nest subsurface.

Step 2: The Build

I made a short video that demonstrates various capabilities of the tool. Since particulars as to dimensions will vary depending on the brand employed, I have omitted them for the most part and simply show working concept and key features:

  • Barrel style full body clamp with easy on/ off mounting
  • No physical or mechanical modification to the tool is needed
  • Slotted work surface table, adjustable in/ out, is centered with disk
  • Bench hook (lip) on front edge of base promotes immovability using just a single clamp
  • Simple "T" style adjustable miter gauge aids in precision work
  • Disks can be changed while tool is mounted by simply loosening and sliding off slotted work table
  • Easily accessible on/ off switch
  • Simple construction allows fabrication from cutoffs and drops
  • Model-makers especially, will find this tool most useful

Step 3: Parting Thoughts

For enhanced safety, a guard would be advisable, however I have yet to install one.

Hearing protection is a must for all but the quickest uses.

I use mine outside, so dust collection is not necessary, but a small shop vacuum would be beneficial if used indoors.

I should have used a fresh disk for the video, it would have cut cleaner with no burn marks.

This is a perfect example of when it is more efficient to put work to the tool instead of tool to the work. Much smaller, finer items can be processed with this setup than can ordinarily be had with the tool used in it's native form, also operator comfort is greatly increased since it is held securely in place.

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    17 Comments

    When the disk shatters you better be wearing a face shield.

    Make a steel disk to fit the grinder rather than using a fibre disk.

    Trust me. They aren't made for side pressure and they explode outwards at high speed. The cuts don't heal cause they are full of grit and it can easily take an eye out.

    You have omitted the instructions - admitting it is not an instructable.

    I'm here for build/make instructions, not use video.

    I agree with you about those who use the site as a link farm to promote their video channel, but if you follow the series as linked in the Instructable, you'll see this is simply more like a "Part Two" construct:

    https://www.instructables.com/id/Renewing-Sanding-D...

    This part demonstrates a potential use of that Instructable content, and for reasons cited, hard dimensions are omitted due to a number of variables.

    Again, I'm with you on the issue of video only posts, and thanks for your observation.

    I like you sander , I need to make one ! Save money buying belt for my belt sander ! Thank you !

    Thank you for the positive comment and yes, many times a large sanding machine is not needed and a small one will serve just as well.

    I like you sander , I need to make one ! Save money buying belt for my belt sander ! Thank you !

    I like you sander , I need to make one ! Save money buying belt for my belt sander ! Thank you !

    I like you sander , I need to make one ! Save money buying belt for my belt sander ! Thank you !

    I like you sander , I need to make one ! Save money buying belt for my belt sander ! Thank you !

    I like you sander , I need to make one ! Save money buying belt for my belt sander ! Thank you !