Variable speed disc sander build thread

G

gixxer

Joined
Sep 21, 2006
Messages
1,472
Ok, I have already shown off the goodies that came in the mail, time to build. In hindsight, I would have had the sheet metal shop shear the 1/4 plate into more pieces so I did not have to use so much time and effort to cut the stuff myself... With the most ineffective tools that is. So let's recap, shall we?

Teco FM50 VFD, NEMA 4 enclosure
FluxCapacitor.jpg


3/4hp 3ph 230v motor
5.jpg
 
I got two 12" square 1/4" mild steel pieces, one for machine base, and the other for smaller pieces, worktable rails, legs.
2" square 11ga tube for motor pads
1" square bar for worktable base
The motor pads, worktable base, leg mounts are held with 1/4 20 hex bolts, all ends tapped. I am going to get some knobs to mount on the end of the 1/4" bolts that are for worktable removal.

4x 3/8 bolts to mount motor to pads
4x stanley industrial doorstops for rubber feet

I was debating whether to have the disc right up to the edge of the machine base, overhanging, or inset. After not much thought, the disc is "flush" with the machine base.

The base is fairly stable with the motor mounted pretty much on the middle of the base. It jsut kinda ended up that way. If the base were smaller, I would have adjusted for CG moreso than disc location.
So, I will take more pics of finished individual parts, but heres a couple pics of progress.

tapping base for pad bolts
Tappingquarter20.jpg


"dry" fitted motor pads and motor
mockupforfit.jpg


measuring for worktable mount placement
worktablebasemockup.jpg
 
My "redneck" chopsaw has been working fairly nice. I got a 7 1/2"x1/8" norton abrasive blade and mounted it in our table saw. Works pretty nice in a pinch (pics tomorrow). A real chop saw is in the works shortly. I was blown away by the chop saw they had in the sheet metal supply joint. The disc was 22", with a 4' handle on the thing. They were bringing 8" (maybe bigger) I beams over on forklift, and that thing chopped em like it was nothing! Shot sparks out like 15ft too! Definate lack of horsepower in the workshop compared to that thing. As a matter of factly, I found the same model on E bay.
http://cgi.ebay.com/EVERETT-ABRASIV...-20-AA-22_W0QQitemZ140100666917QQcmdZViewItem
 
Well, spent most of the day cutting the 1/4" plate for worktable and legs. Drilled and tapped holes for worktable base mounts, ground bolts flush for "cleaner" look. Heres a photo of the doorstops mounted for feet.
Machinefeet.jpg
 
ok, got the table legs done, fitted, one table pivot mounted, drilled, tapped. The end is near. I drilled and tapped for 4-40 bolts for pivot and table mounts to pivots. I went with small bolts since I am not going to use this to hog metal, more for fine detail. Oh yea, if anybody asks, be careful using a 1/8' end mill cause if you push it the bit will go "PLINK"! and snap real quick. Ask me how I know this. Still looking at my design for taking the table off for paper replacement. not exactly the most efficient method, but it will work. I think I am going to hold off on slotting the table legs for 100% adjustable miter till a later date. For now I can use different lengths of 1/4"sq stock on the back side of the table to base. Pics...

Fitting table legs
fittingtablelegs.jpg


table pivot
tablepivot.jpg


table test fit
testfittable.jpg
 
Well, it is structurally done!! Definately not the most efficient design, but it will work. Later on down the road (I.E. when I get a vertical mill) I will set it up for miter. I have the rear support tapped onto the main table legs midway to make room for sliding once I get the slots milled. I shall do wiring this weekend! Hopefully I will be using this piece by mid Sunday. Got a 60A single breaker box made for outside A/C shutoff to use as a main power switch before the VFD (I also like the padlock ring, now try to use my stuff while I am gone!!). Check it.
http://electrical-supply.hometownhardware.com/Load_Center/Square_D_Co/A/C_DISCONNECT-s537985.html
The power is still going through a 30A breaker, so it is only gonna be used for a switch. So, heres the last construction photo. Last photo of the thread will be everything wired, installed, hooked up and running.

baseisdone.jpg
 
I like it very much. If you replaced the 2 diagnol supports on your bed with sq tube with a set screw and sq stock wouldn't its angle be adjustable and very sturdy?
 
Square tube would be definately more sturdy than my setup now. If one were to use this for serious grinding, then my setup would definately not work. There is not too much play in the parts when the bolts are loose, and when everything gets re tightened it pretty much comes back to a hair around 90deg to the disc. It is more solid than it looks.
 
:mad: :mad: :mad: I will use the emoticons instead of swearing. I have busted my tail for over a week getting this thing together, and now the VFD is tellin me low voltage!!:confused: I checked the input voltage twice with a multimeter, so now I have to send it back.
 
:foot: I guess when installing slimline 2 pole breakers the goal is to get it on =TWO= buss bars, not on the same one. VFD works, now have to program it. Talk about a rollercoaster evening. This all transpired when the dryer stopped working right after we swapped fattie breakers for slimlines. Move a single, bump two doubles, everything is swell.
 
Well, call this thread officially done. Mounted the VFD to the wall, on the end of a pair of stacked 2x4's tapconned to the wall. that makes the VFD stand off the wall so I am not reaching to turn it off. I tried changing the paper by only removing the worktable, and it only took a few seconds to take it off. there was enough clearance to get the paper around the legs without touching the disc till I was ready to set the sheet. It definately took longer than I anticipated to get done, but it was pretty nice to get it going (no electrical fire, YESS!!!!) and then you can see how really flat you can get your flat grinds after using the belt.

Done.
sanderdone.jpg
 
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