I make objects from recycled pallet wood. The main problem is the recycled wood is very rough and sometimes dirty. I can't afford a drum sander or a planer thicknesser but had a dying angle grinder that was itching to become something better. I decided to design a box to run the lengths of wood through. In the bottom I wanted to fit the angle grinder fitted with a flap wheel so that it took a set amount off the wood as it passed through. Now that I have expertly and succinctly described my wondrous invention, you had best look at the pictures instead.

The only outlay was for an offcut of 13mm plywood £2.00,  a length of m5 threaded rod £2, and some wing nuts and t nuts @ £1.
as I already had the angle grinder and the flap wheel. I have included dimensioned Sketchup diagrams and these were based on a 115mm grinder and with sufficient depth for 20mm thick wood. You may have to adjust your dimensions but none of this was rocket science.

Step 1: Getting Started

The width of the boards is determined by the width of the flap wheel. I didn't want any gaps between the uprights and the flap wheel so that the unsanded board could miss being smoothed. I was using 13mm plywood so the width was wheel diameter + 13mm x2.
I didn't want the box to be too long as the wood generally comes out at 80 to 100 cm and as it would be fed by hand, it needed to emerge from the end of the box before the end of the wood entered the front of the box. I decided 500mm would be adequate for this purpose.

Once cut to length and width I cut the hole for the wheel with a router, this could easily be done with a jigsaw but I was lucky enough to be able to peg the router in the centre of the circle through a hole in the router mounting plate and the bit tracked out at the right circumference to cut the hole.
<p>Wow, Please help me to write this type of spamming content!</p>
and the flap wheel has an angle itself, do you corrected it to make the flap wheel flat or isn't that not needed?
doesn't it sand to hard ?
<p>Nice idea, now that you've had it a while can you give us some idea how often you need to change the flapper wheel? How much wood you're able to sand with one?</p>
Hi <br> <br>Great idea and use of the angle grinder. I think the dust collection could be improved by having the port on the side near the rotating flap sander. The rotation could &quot;throw&quot; the dust into the dust port to be removed by the vacuum cleaner. <br> <br>Kind regards <br> <br>Peter
This is a really good idea!
I like this. I'm gonna knock one together myself. Thanks for the idea!
I use an angle grinder nearly every time I work with wood. It is a tool that is under utilized in my opinion. So great at removing large amounts of wood very quickly. Nice idea for the &quot;planer box.&quot;
i love this fare play to you to give this a go well done 10out of 10
What a great idea! I have lots of rough wood left over from a fencing job and this is perfect for cleaning them up! Thanks!
It might be handy to mount two more combs on one side of the box, to hold different widths of board steady when sanding.
Very cool idea! Now to make one.
I used to work very hard sanding pallet wood down with belt sanders. Then I got a thickness planer and life got a lot easier for me. I mean imaging trying to sand this much off wood
I used to work very hard sanding pallet wood down with belt sanders. Then I got a thickness planer and life got a lot easier for me. I mean imaging trying to sand this much off wood

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Bio: I work on the railway to pay the rent. I was recently left with a disability after getting knocked from my bicycle and I am ... More »
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