Due to the noise and the inefficient dust collection of belt sanders, I was thinking about another way of sanding that would meet my needs as well as improve the outcome of rough sanding. The variable frequency drive enabling to slow the shaft speed, I wondered if a 5mm thick aluminium disk would be enough rigid and steady to enable sanding on the top side and thicknessing from below. I was pleased with the result under some conditions. The disk holds a 40 grit sand paper on one side that allows passes up to a third of a millimetre whereas two tenth of a millimetre can be sanded with the 80 grit, on the other side. I keep using the random orbit sander to smooth but the thickness sander on the spindle moulder replace the belt sander most of time, at least for workpieces up to 250 mm wide.

I paid a visit to the old metal dealer and found out a very flat aluminium plate that would perfectly match my wish. After drawing a circle some millimetres beyond the aimed 305mm diameter, I started rough cutting the shape with a jig saw and a blade for metal at the lowest speed stroke. By chance I got an extra and useful 125mm square angle drawn below.

Then I drilled a rough aperture in the middle of the disk and built a specific template to adjust the centre hole with the spindle moulder shaft diameter. A 35mm height spacer of the spindle moulder shaft was locked on the bench top and I clamped the disk above that fixture. The flush trim bit copied the spacer hole in the aluminium disk and I had just to slightly sand the internal edge so that closely fitting the shaft diameter.

I got 303 mm in diameter after sanding the external edge with that circle fixture. The disk seemed flat but wasn't and required balance. I locked a power drill with an inner tube of a bicycle wheel along the power feed unit and clamped a sanding disk in the chuck. That assembly rotated around the power feed base so that sanding the full surface of the aluminium disk. Then I switched on the drill and rotated the aluminium disk by hand. The disk was lifted step by step with the spindle moulder micro adjustment. Straightening the two sides of the disk was needed and took much time.

After scouring the balanced disk, I cut some strips of sand paper and stuck them with double-side tape. It remained to set up the right fence and perform some trials.

Hung on the beneath side of a shelf just over the its matching fence, the sanding disk was easy to put away.