Pattern sander ideas

[GREG IN MALAD]

I am in the process of building a pattern sander, and since I tend to over-complicate things, I was hoping somebody could post some photos.
                  Thanks, Greg

[bjansen]

How are you planning on builing it Greg.  

I've thought about this quite a bit too. It would be great to have one and then on the other hand I think maybe the Luthier's friend Robosander attachement with 36 grit on a drill press might just do the trick as well (and cheaper).

[walkabout]

by pattern sander do you mean an attachment that will allow you to follow a premade wooden pattern? if so have a look at this page, its a neat little tip that would work pretty well with a drill press sanding drum.  http://www.woodworkingdrumsanding.com/page7.htm   the"printer friendly versions" have alot more info too.

[walkabout]

i saw the luthiers friend awhile back, it could be replicated with a few pieces of wood, a spring or two and some barrel nuts depending on how minute your adjustments would have to be.

[Chad Orde]

Greg I have thought about making one too and had the recent idea of using a router table with a pattern bit with bearing on bottom I know Freud makes a couple long bits in the diablo line.
 http://www.freudtools.com/p-177-top-bearing-flush-trim-bits.aspx
I have a edge Jet edge sander but modification would be hard not to mention time consuming. I also thought why not make a sander set up with 2 or 3 stations. I have a pic some where I will try and find and post.

[GREG IN MALAD]

I tried a robosander a few years ago and it didn't work for me, The rubber drum deforms and leaves high and low spots. The biggest problem I have right now is lack of space in the shop, so I need something compact. I considered a router table with a flush trim bit but I would prefer a sanded finish over a smooth one.
 What would be ideal for me is a low speed motor, mounted under a table like a router, that used a metal expanding drum to hold the sanding sleeve with a guide bearing. However I have never seen a metal sanding drum. I may be overthinking this but I would like to get it right the first time.

[walkabout]

i find that my drill press with a sanding drum chucked in it works pretty well after you get the hang of it. with steady slight pressure and controlled feeding you can pretty much take anything down cleanly and uniformly. ive been using it to finish edges on a laminate project i have going and after i got a piece set under it with a hole for the drums edge to set in im wondering why i hadnt done it sooner. on stuff thats 1/4" or so thick its actually faster than using a surform, more controlled and a nice flat smooth edge. you could probably apply something like this to your own design only upsidedown, and get the same results.

[Gundog68]

I did it my way:

 http://www.fletchers-corner.de/index.php?topic=14171.0
Maybe you get the idea ?

Gundog

[jess stuart]

I have also not been totally happy with the robo sander.  Same problems as Greg, I have found out it is best not  over tighten the nuts, tends to compress it out of round.  Another problem at least in my case I have a cheap drill press with some play.  Might work much better with a bigger and better drill press.

[GREG IN MALAD]

Gundog,
That is exactly what i'm looking for. How does the drum expand and grip the sanding sleeve?

[Chad Orde]

Here is a link to get sanding drums but they are not cheap, my edge sander came with one but no way to add a bearing.
Bow Making Machinery
Heavy duty drums for making your own sanding machinery.
 This is Fedoras archery products page. I bet you could order replacment drums for edge sanders that might be less expensive.

 http://www.tradmaterials.com/id58.html
Heavy rubber serrated wheels. Custom designed for your individual machine.
6"x 4"x .75"- $195.00
6" x 2.5" x.75"- $125.00
3.5"x 4.5" x 1" - $85.00

Special air drums for all you flat and contour sanding.
8" x 9" - $182.85
3" x 9" - $123.00
2" x 8 " -$98.15

[No-sage]

I bought these metal sleeves that go on my robosander.  I got both the 24 and 36 grit sleeves.  There is no flex in them, and they seem to last forever.

Here is the website:   McMaster-Carr  

The part number is: 4727A43

[Gundog68]

Originally posted by GREG IN MALAD:
Gundog,
That is exactly what i'm looking for. How does the drum expand and grip the sanding sleeve?

The drum does not expand. There is a flat spot on the cylinder where the sanding paper overlapped. It is put on with carpet-tape. So i can use normal sanding paper. I use this drum only for the last passes to get to the template. Before i use the bandsaw and an edgesander to get near the template line.
(The material costs for me: < 20$)

Gundog
G1

[GREG IN MALAD]

Thanks Gundog,
 I never would have thought about carpet tape.

No-sage,
 Even at $48 per sleeve they look like a bargain, and would make a robo-sander work.

d-i-y bowhunter,
 today I found a variable speed control for a router, And have been giving the router table a second look. That 2" x 2" flush trim bit would work fine if it were slowed down, turning it 27,000 rpm made me very nervous.
 
Thanks for all the great ideas.

[Robertfishes]

I also bought the metal sleeves that go over the rubber drum, this one is 36grit, I'm gonna buy the 60 grit one next, in my opinion the 36 one is a little rough, so I end up sanding out the roughness(grooves)in my riser with a 50 grit drum sander(not the robosander)so my glue lines look better..