Do you have sanding disks spread all around your shop? I’ve got the solution.
I’ve lost count on the number of times that I have reached for what I thought was a 120 grit sanding disk, only to find out that it was 60 or 400 grit. When you are mid-project the last thing you need is something that holds you up. With this sanding disk organizer, you can keep all your sanding disks organized by grit and/or size. We have plans available below which include a cut-list, instructions, and a Sketchup file.
- SawStop 3HP Professional Cabinet Saw
- Bosch 12-inch Miter Saw
- Irwin Maples Dado Stack
- Ridgid HyperDrive Brad Nailer
- MICROJIG GRR-RIPPER 3D Pushblock
- Woodpeckers 1281 Woodworking Square
- Amana Tool Countersink Bit
- Pony Jorgensen One Hand Clamp
- Dewalt Random Orbital Sander
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Step 1: Break Down 3/4" Plywood
As with every project, I reference my cut list and begin the process by breaking down the sheet goods by ripping all my 3/4" plywood parts to width. I go through all of the pieces and mark my cuts based on the cut list. Using my miter saw, I cut all of the 3/4" plywood pieces to length.
Step 2: Break Down Remaining Pieces
Next, I rip my 1/4" plywood to width to make the sanding disk trays. Then it's back to the miter saw to cut the 1/4" pieces of plywood to final length. The plans call for 1/4" plywood for the front tray pulls. I happen to have to spare maple offcuts, so I used those instead.
Step 3: Make Dados for Trays to Slide In
I change out to a 1/4" dado set on the table saw, and make a test cut to ensure the tray slide in and out smoothly. I continue to measure down every 1 3/4" and make another dado, 7 in total, for each tray to slide in.
Step 4: Assemble the Sides
Add some glue to the left side piece. Use some corner braces and clamp the side and back piece together. Attach the side to the back piece using 1 1/4" brad nails.
Repeat this process for the right side. Add the glue. Add the corner braces and clamps. Secure with 1 1/4" brad nails.
Step 5: Add Bottom and Top Shelves
Move on to adding the bottom piece. Attach it to the rest of the assembly using 1 1/4" brad nails.
Take the top shelf piece and add some glue to the back edge and both side edges. Secure using brad nails on all three sides.
Step 6: Prepare Parts for Tray Assembly
Start off by marking out the locations for where the dowels will be inserted. Tape all 7 tray pieces together and hop over to the drill press to make the holes.
Using a cross-cut sled or miter gauge, trim the dowel down into 1 1/2" pieces. You will need 14 in total. I use one of the sanding disks to round-over the edges of the dowels so the disks can slide on and off easier.
Step 7: Assemble the Trays
Apply a small amount of CA glue to the dowel and insert it into the hole you made previously in the tray piece. Once both pieces are secure, spray the joints where the dowel and trays connect to make that secure bond. Attach the tray pulls using the CA glue and activator for a strong joint.
Step 8: Load Up the Tray With the Disks
Take the trays and add one grit of sanding disks to each tray using the dowels as a guide to keep the disks in line. I added the number grit to the front of the tray pulls so it will be even easier to pull out the tray that is needed for the project at hand.
Step 9: Add the Cleat and Hook
Take the french cleat piece and secure it to the back of the assembly using glue and brad nails. Using a countersink bit, make 3 holes in the cleat. Secure it with 1 1/4" wood screws for added strength.
If you want to hang the cord of your sander, select the location and attach it using the supplied hardware.
Step 10: Hang It Up and Add the Trays
Hang the whole assembly on the french cleat wall and add in the trays. Place your sander on the top shelf and hang the cord on the hook.
Step 11: Get the FREE Plans!
Get them here.
Step 12: Final Thoughts
I hope you enjoyed this shop project. This sanding disk organizer is a great addition to my small shop workflow. My french cleat wall is always expanding and changing regularly, and this project keeps that process going. Over the past year, I have noticed things that I need out of the cases so that I can access them more easily. If I have to search and move things around, then I probably will end up using something else. These shop projects are all about making things easier in my small shop.
If you have any questions or comments, please leave them below, I would love to hear from you!