81 - Ultimate Sharpening Station, страница 37

Step-by-Step

Drum Assembly

The first step in making a sanding drum is to cut a set of MDF disks to form the core. You'll need six disks for each 5V2"-long sanding sleeve.

MDF Core. For an easy fit, I used a circle cutter to size the MDF disks so they just slipped inside the sanding sleeve (top left photo below). For more on using a circle cutter, turn to page 30.

Working with Rubber. The next step is to cut a set of rubber gaskets. I found it almost impossible to cut perfectly circular gaskets from the V4"-thick neoprene rubber material I used. (For sources, see page 51). So instead, I cut oversized squares and then punched a hole for the drive shaft in the center of each gasket (top right photo below).

Assembly. To assemble the drum, cut a piece of W threaded rod to length Then use epoxy to glue a single MDF disk and washer in place, leaving room for the nylon spacer (lower left photo).

The rest of the drum goes together by gluing alternating layers of MDF and rubber gaskets. Just be sure you don't glue these to the

drive shaft. This way, when you tighten the coupling nut, the "loose" MDF disks and gaskets will compress without any problem.

After adding a washer and coupling nut at the top, you're ready to trim the gaskets flush. To do this, I "snugged up" the coupling nut just a bit and then used a sharp chisel, like you see in the photo above.

A Assemble the Drum. To assemble the drum, start by gluing a washer and MDF disk in place near the end of the drive shaft. Then screw the nylon spacer in place.

A One Layer at a Time. Next, build up the assembly by alternating the rubber gaskets with the MDF disks and gluing them together with contact cement.

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A Size the Disks. The first step in building a sanding drum assembly is to use a circle cutter to size the MDF disks so they just slip inside the sanding sleeve.

A The Gaskets are Next. After cutting squares of rubber to size, create a hole for the drive shaft with a hollow steel punch.

Trim the Gaskets.

A sharp chisel makes quick work of trimming the gaskets flush with the core of the sanding drum.