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shop Made Sanding Disk on Table Saw

I had been thinking about such accessory since I connected a variable speed drive on the combination machine but no commercial sanding disk for table saw met my need. The wagon carriage was so close to the blade that just some tens of a millimetre would remain with a one millimetre thick abrasive stuck on a 2.2 steel disk. Eventually I made the decision of cutting a balanced disk from a steel saw blade. It would probably turn out a hard task but was the only way I found. I bought a new 350x2.2 steel saw blade and quickly became aware the whole thing should be about patience and safety. The metal body blade was hard and heating would probably lead to twist the disk but over all, the thin cut-off wheel for stainless steel was producing so many sparks that I firstly decided to carefully clean the work shop in order to avoid fire hazard.

Overview


A thin cut-off wheel can solely withstand straight cuts and may break or worse piercing the blade body as well as not properly guided. The below fixture purposes to vertically clamp the steel bade and horizontally guide the small angle grinder. Firstly a plywood plate with a hub matching the blade arbour hole was firmly screwed on the front side of the bench. It also accommodated a pin fitting the clearance between two teeth that enabled quick repositionning. Two clamps quickly locked and released the saw blade. Secondly a straight wood-like board was clamped onto the fixture frame. The U shaped wheel guard of the angle grinder gliding along that track allowed enough stability to keep the thin wheel horizontal provided I was always performing the same left to right movement.
The blade was divided into sixteen segments on each face with an offset angle of about ten degrees aiming a thirty two final shape. Given I knew about nothing as regard the bade behaviour facing heat, I decided to cut step by step with only three strokes at each time then rotating the blade at a 180° angle, repeating that operation on the first face then switching to the other side and so forth. After six passes on each segment and many hours of hard work I got the shape without any twist.

Cutting


Here is a metal lathe made up of a bench grinder bolted on the bench top and two clamped spacers holding the hub ever used above. A screw near the grinding wheel locked the plywood plate and allowed fine rotation adjustment. Grinding some tens each pass the thirty two side shape turned into a circle in five steps. Finally the disk was mounted on the saw arbour (about 1500 rpm) and became a perfect circle after sanding the edge. One more time I didn't feel comfortable with sparks and sanded from the rear blade in order to prevent sparks from entering the combination machine.

Balancing


The hard task being done I cleaned up the work shop of that appalling black dust and scoured the balance disk then cut three length of sanding paper and stuck them with thin double-side tape. With a 45° tilted blade, a half a millimetre only remainded between the sand disk and the wagon carriage. It worked well but that experiment reminded me how much I love wood and metal seems repulsive. The sanding disk is put away as any other saw blade.

Complete


Sand paper speed related to Diameter, in meters per minute
Ømmrpm 1400 1600 1800 2000 2500 3000 3500 4000 4500
300131915081696188523562827329937704241
250110012571414157119632356274931423534
20088010051131125715711885219925132827
15066075484894211781414164918852121
100440503565628785942110012571414
50220251283314393471550628707
Circumference in meter : 2×PI×Rmm ÷ 1000 = 3.14159 x Ø mm ÷ 1000
Speed in meters per minute : Circumference m × Rpm