Light-Duty Custom Spools for ABS Plastic

 by MercuryCrest
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Step 3: Prepping the Outer Discs....

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I cut the outer discs on a bandsaw, knowing that I would achieve something less than perfect circular-ness. This is why god invented bolts, wingnuts, drill-presses, and circular sanding discs all on the same day.....

After seeing my horrifying freehand interpretation of circles, I realized that I could use the mid-point as a guide.

Essentially, I used a drill press and drilled down straight through the "X's" that I left as the center-points of my circles. From here, I inserted a bolt that was about the same size as the hole and added a wingnut that, when tightened, aligned all of the "circles". From here, I started making passes with the disc-sander. The trick here is to keep the piece moving, rotating against the sanding disc.

You can see the before and after shots above.
 
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