2016-10-11 (Tu) Power Drill to Belt Sander Conversion

All the parts were finally printed correctly and the unit was assembled. It was as rigid as I had hoped it would be. Before the metal braces were installed I was worried it would be flimsy or overly flexible.

Assembled unit

The drive pulleys, which connected to the drill, were reprinted with 100% infill. The resulting prints were noticeably heavier than the first prints which were only 10% infill. Nylon insert lock nuts were installed around the drive wheels instead of regular nuts.

Nylon insert lock nuts attached to drive shaft

A power drill was connected to the drive shaft and a wooden block was formed to prop up on end. This block may need to be replaced by printed feel in the next revision.

Power drill to run the sander

Two videos were made which showed the sander in operation. The first video just showed how the drill could be used to drive the sander on a bench top while the second video uses the sander as a handheld unit.

Benchtop sander

Handheld sander style operation

Not even a single gear was entirely sanded before problems arose. Friction between the drive plate and a drive pulley was where most of the problem was. Some adjustments were made but the two eventually friction-welded to one another and had to be broken apart with force. Spacers around the bearings will probably be the next necessary step.

Fortunately, the structure held together and some gear sanding was done. The process, when the sander ran, was easy and effective for shaping gears and this project should be a valuable addition to the tool bag.

Gray dust from effective sanding and friction burns from ineffective alignment

Friction damage on a freewheeling pulley

Drive pulley and drive plate damage from poor spacing


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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2016-10-07 (F)