Instructables
I always found myself needing a bench mounted disc of belt sander for rounding edges of wood mainly when building wooden toys for my son. Being a tight ass meant that shelling out NZ$180 for a unit like the one in the photo was not an option especially since i could get a bottom end angle grinder for only NZ$15 + a snading disc attachment for $NZ8

Mount it to a box, add a solid work surface and TADA a 10000rpm wood destroyer..!!

 
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Step 1: Find a suitable box

First find or make a wooden box - at least one side and the top must be pretty square to each other. I used an old nail box.

Step 2: Procure cheap angle grinder

Buy the cheapest angle grinder you can find, this one cost me $NZ15 for 10,000rpm and a 12 month warranty. 100mm is the smallest available but you could get bigger.

Also get a disc sanding attachment, either the sticky back type or the velcro type will work.

Discard the angle grinder handle and safety guard, then attach the sanding disc to the spindle.
holeag8212 months ago
Build wooden toys for your son? Very loving father, must support. In addition, the use of angle grinders this idea is very good.
Rajabbek1 year ago
Thank you, that I was looking for such a structure.
genius! I need this in my garage.
Thanks
Greg
Going to do this with a old grinder wire a dimmer switch inline a foot pedal and drill some small holes in the box where the dust will fall through and be sucked in by a vacuum
Attach an inline RPM controller and wire tie the control knob to the base, then you can easily attach a 7 1/2" disc and boom! you have full size sander. It cut down on the torque 'cause it' not geared down, but still very effective.
Mr. Rig It7 years ago
Great Idea! Now I can use my angle grinder for yet another purpose. I currently have it set up as a cut off saw. It works great, come to think of it I may have only used my grinder twice as an actual grinder.
Good Job.http://www.instructables.com/id/E6LE48HQPDEQHOA8TK/#
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Tallman7 years ago
What if you attach a vacuumcleaner to the box? Then you have less dust in the working area. And saves time cleaning it. To reduce the noice it's also possible to mount a beam slantingly to the sides of the box. So that the sides of the box won't function as a soundboard and won't resonate. Note that the beams are off centre and are unequal placed. That will prevent resonation.
box.bmp
lemonie7 years ago
Cable-ties, fantastic. Surely cable-ties are one of the better inventions of the 20th century?
pfred18 years ago
This thing must rip stock down! I have seen discs you can put on a tablesaw, or radial arm saw to attach discs to. RPM and noise might be a bit saner with those. Maybe one could use a beat old sawblade to the same effect? Grind the teeth off it or something. Me, I actually have a stationary disc sander. Don't use it very much but I got one. My belt sander is a rig I should post that someday. The belt sander I use a lot. One of the angle grinders I have I have dedicated to belt sanding too, and I made a fixture to clamp that down. A piece of wood that bolts to the handle thread. Throw that in a vise and you're good to go!
Robotrix8 years ago
Could you maybe fill the box with something to help cut down on the noise? Maybe some foam panels along the inner walls. That hollow box must make a great resonating chamber!
divxnz (author)  Robotrix8 years ago
Good idea... it surely howls... I just did a decibel test and it make 98dB at about where your head is when using it - definitely earmuff material...
divxnz (author) 8 years ago
Thanks trebuchet03 ... its my first instructable...
trebuchet038 years ago
I vote this... at the very least, honorable mention worthy for the project of the month contest.