2016-10-08 (Sa) Power Drill to Belt Sander Conversion

The current revision of the parts had not finished printing but the threaded rods could be sized with the last revision of parts. Unfortunately, the parts will have to be disassembled after sizing and cutting all the threaded rods. A rough estimate was taken by laying out the parts with the belt installed. Having the belt installed was the most important, and difficult, feature.

Parts in their approximate locations

Marks were made on the threaded rod but they were all made beyond where they would likely be needed. The design of the sander intentionally allowed the threaded rods to be lengthy since it is possible to shorten one side while lengthening the other. With long enough bolts it would be possible to run the sander with only one pulley and one drive wheel. Threaded rod was cut on a chop saw with fiber cutoff wheel. After the rods were cut each end was rounded on a large belt sander. This belt sander was ideal for metal but did a poor job with plastic as I found out when I tried to sand the gears.

Parts with four cut rods

While designing the parts it was important to keep clearance around the bolts so a nut driver could reach them. Two nut drivers were used to tighten the bolts on the drive plate. These bolts kept the frame from wobbling. They weren't perfect.

Nut drivers used to fasten printed plates together

Two of the threaded rods were given lock nuts and aligned uniformly. The next pair was given a pair of lock nuts at one end and ordinary nuts for the other side which were used to adjust the tension on one of the pulleys. The desired triangular shape finally arose. Many of the parts were too weak to handle the stress of the threaded rods so a couple of metal angle braces may be enough to reinforce the shape.

The desired shape but not enough strength yet


The rest of the posts for this project have been arranged by date.

First time here?

Completed projects from year 1.

Completed projects from year 2.

Completed projects from year 3.

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2016-09-26 (M)