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Thread: Quick and Dirty Drum Sander Stand

  1. #1
    Join Date
    Oct 2006
    ABQ NM

    Quick and Dirty Drum Sander Stand

    Not as quick as I would have liked, and a little dirtier than planned, but I finally did a bit of flatwork this past weekend and slapped together a stand for my newly-acquired drum sander. I was able to put together a flip-top rolling cart for the cost of a sheet of plywood, three 2 x 4 studs, and a few bucks worth of nuts and bolts (plus a few other bits of plywood I had laying around the shop). I didn't need fancy, but I wanted stout. I didn't take a good series of progress photos, but I grabbed a few along the way.

    The basic plan was for two 2 x 4 frames - one on top and one on the bottom - with 3/4" plywood sides. (The 2 x 4 studs were milled down to 3 1/4" x 1 3/8".) The bottom frame would get a skin of 3/4" ply on the bottom, and be glued and screwed to the sides. The top frame would be skinned on both sides with 3/4" ply and mounted with bolts and T-nuts to allow it to swivel and flip over. One side would have the sander and the other side would just be a flat work surface the same height as my tablesaw.

    I haven't used my vertical tablesaw sled in a long while, but it sure came in handy for cutting the box joints for the frame.

    Attachment 60861

    I used the Freud Box Joint blade set to get perfect 1/4" wide flat-bottomed cuts, and used the Incra fence on my saw to move the sled exactly 1/2" at a time.

    Attachment 60862

    Gotta love the Incra fence on a tablesaw. This took me about 5 minutes to knock out, including setup time...

    Attachment 60863

    The obligatory glue-up in the clamps shots...

    Attachment 60864 Attachment 60865

    I didn't get any photos of the plywood cutting. You've seen plywood being cut, right?

    Since the upper frame is a closed box, I wanted to be sure the T-nuts don't get pushed out when driving the bolts to support the top. A 3/4" sheet metal screw on the edge of each T-nut should solve that problem...

    Attachment 60866

    The base is very basic. As I said, it's just glued and screwed to the sides. The casters came off one of the Harbor Freight moving dollies they have on sale for $9.95 periodically. Buying those dollies is the cheapest way I know to get four 250 pound rated casters.

    Attachment 60869

    One tricky part was mounting the sander onto the swivel top. The base of the sander has four holes and threaded studs welded onto the backside of the channel steel that makes up the base. These studs are on the inside of the frame, hidden and out of reach. The idea is that you can simply run a bolt from underneath through a benchtop and screw it into the threaded stud. Unfortunately, a couple of these studs were broken off on this sander, so I needed a way to access the inside of the frame channels to hold a nut. To do this, I cut a couple of rough access holes in the plywood under the sander. Here's a photo of the swivel top, with the sander in the inverted position and the smooth, blank top removed. I was able to reach into those holes to hold the nuts that replaced the missing threaded studs...

    Attachment 60867

    Here's the stand with the flat top installed. Meet the new horizontal space in my shop to collect stuff...

    Attachment 60868

    And here's the top flipped over with the sander ready for action. I took the extension tables off the sander because I simply don't have the real estate in the shop for that long of a machine.

    Attachment 60870

    Both tops are just screwed on, so I can get back inside if I ever need to access the sander mounting bolts. (Such as to temporarily put the infeed and outfeed tables back on.)

    Although I don't plan to make it a habit, it was fun doing some flatwork for a change. I even got to use a couple of my hand planes to clean up a few things and make things match up better. I'm not set up very well for cutting sheet goods accurately, but there weren't any problems I couldn't fix with a sharp plane. Since it was on plywood, I used one of my beater planes, but even so, it was sharp and it made easy work of making things fit.

    So far the only finish on it is a single coat of BLO. I may get motivated to take the sander off someday and put a more durable finish on it, but I wasn't going for pretty, just functional. It should do for now, and it solves my "where do I put this sander?" dilemma.
    When the going gets weird, the weird turn pro. - Hunter S. Thompson
    When the weird get going, they start their own forum. - Vaughn McMillan

  2. #2
    Join Date
    Jul 2009
    Amherst, New Hampshire
    That is pretty neat Vaughn Impressive box joints without a jig

    Good hint on the casters as well. I never thought of that
    Faith, Hope & Charity

  3. #3
    Join Date
    Dec 2008
    Santa Claus, In
    Looks good and the first person to do the group build. "Shop Cart"
    If you don't take pride in your work, life get's pretty boring.

    Rule of thumb is if you don’t know what tool to buy next, then you probably don’t need it yet.

  4. #4
    Join Date
    Nov 2006
    London, Ontario
    Quote Originally Posted by Vaughn McMillan View Post

    And here's the top flipped over with the sander ready for action. I took the extension tables off the sander because I simply don't have the real estate in the shop for that long of a machine.

    Attachment 60870
    Great job, Vaughn. Flip-tops are surprisingly useful!!
    What is your top pivoting on, just some bolts?

    And where did you get that big green multi-drawer cabinet in the background? Looks bigger than a card catalog, and I bet all those drawers are very handy. (I need more drawers in my shop!)
    There's usually more than one way to do it... ........

  5. #5
    Join Date
    Dec 2007
    Los Angeles, CA
    Nice box joints. Simple yet effective design. I like it.
    Chinese Proverb: Man who eats many prunes gets good run for the money.

  6. #6
    Join Date
    Jun 2008
    GTA Ontario Canada
    Very neat solution. But you can admit that you were suffering withdrawal symptoms from not having used your table saw and incra fence for a while. You can come out the closet now flatworker. If you aint one why take on the sander eh?

    Neat trick on the casters, i aint seen that floor you got in prior pics of your shop. Should run well on that. On mine i need min of slightly larger wheel diameter for a unit of that weight.

    Just love the joints, neat upright jig you got to slide across the table saw. What is running in the t track between the two pieces?

    Now someone is going to have to do it with a different joint on the corners.

  7. #7
    Join Date
    Jan 2011
    Spitting distance north of Detroit Michigan
    Come clean now Vaughn, you really seen no reason for a flip top, but... with being the spinny guy that you are............

    Nicely done!

  8. #8
    Join Date
    Aug 2007
    Reno NV
    Seems pretty quick and not so dirty to me.

    I'm a big fan of the flippers!

    Programmer - An organism that turns coffee into software.
    If all your friends are exactly like you, What an un-interesting life it must be.
    "A door is what a dog is perpetually on the wrong side of" Ogden Nash

  9. #9
    Join Date
    Oct 2006
    Central NY State
    Couple of comments -
    really nice work on the finger joints
    great overall design and economical use of materials
    nice looking end product
    Does the sander just flip over without much effort? That is very appealing.

    why do you, an accomplished and gifted turner, need a drum sander?
    Oh never mind, I remember now, you are also the cutting board guy

  10. #10
    Join Date
    Nov 2006
    Constantine, MI
    If that is not stout, I don't know what is!

    Looks great and it has me thinking about building something for my sander.
    “We all die. The goal isn't to live forever; the goal is to create something that will.” - Chuck Palahniuk

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