Transform a drill press into a disc sander with a few simple attachments.
Step 1: Prototype
Threw this together with scraps of wood and a few clamps. Proof of concept... check!
Step 2: Design
The disc sander is drafted in Fusion 360. This way I can refine the shape while quickly visualizing different designs.
Step 3: Ripping, Sanding, Cross-cutting
Everything is made from a sheet of 3/4" baltic birch plywood.
Step 4: Assemble the Base
3 pieces of material form the base. They're held together with drywall screws.
Tip: A workbench makes a fantastic 90 degree clamp!
Step 5: Make the Sanding Pad
Cut a 9" circle out of some more 3/4" plywood to support the sanding pad.
Step 6: How the Sanding Pad Will Spin
Drill press -> right angle adapter -> 2" screwdriver bit -> 1/2" set screw -> sandpaper (and a lazy Susan bearing holds the sanding disc in place).
ALL THE STUFFS
Drill Press - http://amzn.to/21pGQSL
Right Angle Drill Adapter - http://amzn.to/1SIdIAt
Screwdriver Bit (6 pack) - http://amzn.to/1Y2M4Sr
1/2" Set Screw (8 pack) - http://amzn.to/23iEJQ0
Sandpaper (10 pack) - http://amzn.to/1SFO82g
Lazy Susan Bearing (the 9" inch one) - http://bit.ly/1SIdMQz
Step 7: Assemble It
Connect one side of the lazy Susan to the base, and the other side to the sanding pad.
Step 8: Stick Sandpaper
9" adhesive backed pad of 80 grit paper.
Step 9: Attach the Sanding Platform
The finishing touch is to screw on the sanding platform. A few more drywall screws.
Step 10: Lubricate the Bearing
I used silicone spray here, but apparently that's not good for bearings. If you do this, use machine oil.
Step 11: Attach to the Drill Press
I tilt the drill press table 90 degrees, and secure the disc sander with a clamp from the side.
Step 12: It's Sanding!
This project worked much better than I expected.
HIGH FIVE for reading!