Mother's Belt Sander

(Page 2 of 2)

February/March 2001
Story and Illustrations by Will Shelton  
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STEP 4: METAL MODIFICATION

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Starting with the frame ("1" in the "Track Frame" illustration on page 87) drill new holes and make the cuts indicated in the "modified track frame" illustration above. File the edges round. Do same to metal parts "2" and "3". Next, cut the two plastic bearing holders down to two inches. Repeat the entire process for the second drawer slide assembly in the hardware store "kit."

STEP 5: AXLE BEARINGS

Modify the four nylon patio door rollers to turn them into workable drive axle and idle axle bearings (see illustration). First, enlarge the holes of all four rollers to a 5/6" diameter. Next, flatten a side of each of the rollers that will support the axle of the drive wheel. For the two rollers that will support the axle of the sander's idler wheel you need to flatten two opposing sides. In addition, these flats have to be grooved so that they can be held firmly in place by the insides of part "2". Use a hacksaw to cut the flats and a file to shape the grooves.

STEP 6: THE AXLES

Cut the axles for the drive and idler wheels from a length of 5/6" all thread. File the last 3/8" of the drive wheel axle to a triangular shape so that the square chuck jaws of the drill motor will have flat surfaces to clamp down on. Also, you'll need to epoxy the rubber wheels (from the drum sander sets) to these axles and to each other.

To keep epoxy in the right place tape off the end where the nut will go and apply epoxy to the shaft, leaving clear the other end (where the other nut will go). Slide the two wheels into their final position, and tape off the other end. (File the epoxy round after it has cured.)

STEP 7: ASSEMBLY

After modifying all of the components, assemble the metal part of the sander by referring to the "Metal Fabrication" and "Assembled Metal Parts" illustrations. Our sander is designed to use 3" x 21" belts.

When sander is in use, it should be C-clamped to a tabletop or fixed surface. If the belt has a tendency to walk when in use, one of the shafts is not parallel or is out of alignment; adjust as necessary. When you are satisfied with the alignment, use Locktite on all of the nuts to keep them from backing off or use self-locking nuts. Happy tinkering with your newly outfitted shop!

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