That doesn't sound right to me somehow. There's gotta be a way to make patterns that will work with a spindle sander. I haven't done it myself, but here are a couple of ideas:
Originally Posted by Rich Aldrich
1) What if you made your own table insert that was 1/4" (or whatever) thicker than the stock insert? Let's say that the outer "wall" of the insert was 1/2" from the surface of the sanding sleeve. You would make your pattern so that the workpiece would overhang the edge by 1/2". Attach the workpiece to the pattern and with the pattern on the table, underneath the workpiece.Has anyone done this before?
2) Suppose that method #1 didn't work very well because the insert kept popping out (no way to positively attach it, and you tend to exert a lot of lateral pressure against it) or you need to use a small spindle and the overhang gets to be too big to work with. You could do something similar with an "ox yoke" shape, where a thin semicircular arc on "your side" of the spindle joins up with a wide board on the backside. Clamp the board to the table, and away you go!