Fixed Disc Sander from Angle Grinder

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..!!

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.

Comments

[oakironworker]

genius! I need this in my garage.
Thanks
Greg

[stephenniall]

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

[tonguebeetle]

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 It]

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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[Tallman]

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.

[lemonie]

Cable-ties, fantastic. Surely cable-ties are one of the better inventions of the 20th century?

[pfred1]

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!

[Robotrix]

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]

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]

Thanks trebuchet03 ... its my first instructable...

[trebuchet03]

I vote this... at the very least, honorable mention worthy for the project of the month contest.