THICKNESS SANDER

boards, then using this thickness sander to remove the saw marks. The sander also excels at truing up surfaces for cutting boards and other edgejoined projects. The sturdy maple stand will take years of hard use, and the hood keeps the whole operation practically dust-free. The sander adjusts easily and can handle stock up to 2" thick and 12" wide. ake your own thin Mby reszwing thicker stock

Note: Wbile several parts of the base are the same size (A and B, for example; see the Cutting Diagram on page 69), we call them out separately because they are min-or images of each other and need to be machined individually. To avoid making errors, we found it much easier to lay ou t the location of the joints before cu tting.
Build the base 1. Rip and crosscut the feet (A, B), legs (C, D, E,F), top braces ( G), and rails (H, I) to size. 2. Using the Parts View Drawing, page 70, and the Exploded View Drawing, page 68, layout and mark the dadoes, rabbets, notches, and half-lap joints on pieces A, B, C, D, E, F, G, and H. (Since B is the mirror image of A, clamp A to Band mark both pieces at the same time for uniformity. Mark C and E, and D and F the same way.)

3. Using a saw fitted with a dado blade, cut the joints as marked. Make all identical cuts at the same time to ensure accuracy and to avoid having to reset the saw unnecessarily. 4. Glue and clamp the righthand assembly CA-C-D-G) together where shown on the Exploded View Drawing. After the glue dries, locate and mark the center of each half-lap joint, then drill a }4" hole through each, backing the workpiece with scrap

to prevent chip-out. Apply glue and insert a }4" walnut dowel 1}4" long into each hole. Repeat this with the left-hand assembly CB-E-F-G), and sand the dowels flush after the glue dries. 5. Mark and cut a 2" radius on the top ends of A and B, and a 3" radius on the top corners of both leg assemblies. Cut the 01" relief on the bottoms of A and B.

continued

67

~... 17'1." to Insert .....". . <.. . <..'. "d:~ dowel Yo" ~ I threaded insert Fl'"' .. <..__ Yo" F.. <..... . ~~ X 1" RH wood screw """-=<!I..*. x 3Yz" .." hex-head nut <." deep I I for 'I..) .." long 10-24 self-locking nut Yo" clear acrylic J.H...H.) Use a router and Yo" round-over bit on all corners of frame after assembly.. !'---'l..::..." flat washer .. wood screw ~~~~~iJY r. % X 3'1.." rabbet %" deep <.. machine screw I 1Yo" long to fit threaded insert (j) FEED TABLE 5" pulley with %" bore Belt-sand to 8" after assembly 4" T-hinges 1'1. Do not round over 'last 1'1..#6 __ 0 <..-Vacuum-hose adapter 5/64" hole 1" deep H~le to fit adapter 6" -diameter black stovepipe cut in half. Table elevation control assembly (See detail drawing.POWER TOOLS AND ACCESSORIES continued THICKNESS SANDER #6 X %" R. 1 %" walnut over center 7". 1Yo" hole '/:. <... <...i.. <.... : 'I.l!(iLJ...@." h10le(Only one is shown.._.... Hc_>le fit~ ...-. half lap Do not round ..____ Wnut %" walnut dowel R=2" EXPLODED VIEW 68 ...

725-rpm) motor. . HB 'Parts marked with an • are cut larger initially. 2-4" steel T-hinges w/mounting screws. woodworker's glue. epoxy. 2 x 8" continuous hinge w / mounting screws. V4x3V2" carr. bolt w /wing.H. PL-plastic laminate. Please read the instructions before cutting.". mach. HB-hardboard. A-acrylic. 8W 5" 8' 11" 17V4" 15" 3/4" 3/s" %" 2 1 3/4" 2V4" 3W' 12" 5" r 1 lW %" 3/4" 3W 7' 12" . bolts w/washers and nuts. acrylic o leg E leg F leg G brace H rail I rail Feed Table J* table K trim L trim M* laminate N control lW lV2" lVz" lV2" lVz" lV2" 3/4" 3/4" V2" V2" 2 2 2 '1'6" 3/4" ¥4 " 3/4" ¥4" 3/4' 3/4' 3/4" 3/4' Elevation Control o control P control Q control lW lW' lVz" lW 2' 2' R handle S holder T disc U mount block V hood end W strip X sfrip Y block Z pushblock AA handle Remaining Parts 33/4" diarn. page 73.H. PLY-p!ywoodor particleboard. 10-24 x 1" F. 4-% x 1 V4" F. W_.'CD .Bill of Materials Part Finished Size' T Base A foot B foot C leg 1V2" lW' 3W' 3W' 3'12" 3V2" 3'1z" 3V2' 3W' 3'12" 3V2" 12Vs" 1Vz" lW' 12Vs" 30" 30" 353/4" 353/4" 353/4" 353/4" 18" 183. nut and washer. 2" pulley to fit motor shaft.4" 183._walnut. 3/S x 2" carr. machine screws w/self-Iocking nuts. stovepipe 17%" long. contact cement. 5~ pulley w/Sfs" bore. 3/4" threaded rod 12" long w /3-314" nuts. J :. V4" birch dowel.H. strapping tape. V2 x33' V-belt. for additional supplies.H. then trimmed to finished size. #'10X lVz" FH. X 36" Walnut ® fui0 J 1Y:zX5Y:zX12" Maple Material Key: M-maple. wood screws. Supplies: 3/4" walnut dowel. Qty. 0' ®. FRONT VIEW Y:z"strapping tape SIDE VIEW ~ y.i ? '. 69 . %-hp. wood screws. (1. bolts wi%' washers and nuts. 7 I 1Y:z 3Y:zX 60" Maple X CD % X 3Y:zx 60" . #8X 1%" F. screws and 4-%" threaded inserts. #6x 1" R. wood screw. wood screws. 4-V2X4V4" mach.H. #6x%" R.4" 29" 12Vs" 3~" 30" 5" 5" 5" 5" 8" 12" M M M M M M M M M PLY W W PL M M M M M M PLY PLY M M A M M 18 1 2 2 3 2 W L Mat. 6" diarn. See BUYing Guide. 5/S" steel rod 18W long. CD Maple % X 7Y.

9. Then. Attach the T-hinges to the bottom of the feed table. Disassemble and use a router fitted with a Yl" round-over bit to round over all edges of the leg assemblies except at the joint locations and on the top and bottom of both Gs where the pillow blocks will be mounted. Sand the rounded corners and all surfaces smooth. 7. 4. and apply the finish. Build the feed table 1. After the glue dries. I PARTS VIEW RIGHT AND LEFT BASES REAR LEGS FRONT LEGS I f l 70 . Cut the plastic laminate (M) slightly oversize and apply the laminate with contact cement. page 69. sanding flush after the glue dries. Clamp H and I in position to join the leg assemblies. I I I . Then fasten the feed table to the back rail (H) W' from the right leg assembly as dimensioned in the Front View Drawing. Then glue and insert the dowels. Rip and crosscut the walnut trim strips (K. Using a Yl" round-over bit. remove the Clamps and drill two W' holes in each joint. Glue and clamp H and I to the leg assemblies. Laminate the two together. 5. Belt-sand an 8° bevel the length of the back rail (H) to provide clearance when adjusting the feed table. trim the lamination to its finished size (12Vs X 29").POWER TOOLS AND ACCESSORIES THICKNESS SANDER continued 6. Cut a clearance recess for the drum sander in the top center of each L. using a router with a flush trimmer. Glue and clamp one K to each end of the plywood lamination. Mark the edges of H and I that will be enclosed in the joints. 3. rout the outside edges of both Ls. 2. Cut two like-sized pieces of W' plywood (J) to size plus W' in each direction. Glue and clamp the side trim strips (L) to the feed-table assembly. and after the glue dries. 0. with the top and ends flush with the ends of the plywood. trim the laminate. 8.

Drill a W' hole vertically through the entire assembly (NO-P-Q) where indicated in the drawing for the 3. continued %" hole DUST HOOD END Notch out for grease fitting if necessary. 4. P. install the screws through P and into N-O.4" threaded rod. page 69. Screw P to N-O.4" rod. Clamp Nand o together. Trace the outline of the nut and chisel out the excess. 2. Mark the location and drill a }'il" hole through N-O for the ¥SIt carriage bolt.. 5. and one through the side of N Y2" into O. Install the screws. Repeat this with Q. and Q to size as dimensioned in the Bill of Materials.. then thread a 3. and insert the rod through P. 7. The recesses house the nut snugly. then drill and countersink holes for two # lOX 1\.4" screws through the top of P and Y2" into Nand 0 as shown in the Elevation Control Drawing. 6.4" nut on the 3." deep Yo" hole 7/16" deep Cut out to fit pillow block. With a fine-toothed saw. The gaps will allow you to lock the threaded rod in position. Drill and countersink holes for the two #10 Xl \. Cut the elevation control parts N. Apply glue to the mating surface of N-O and P. 1/4" round-over on this edge only 3/8" rabbet ---. below. Clamp Q to the top of P. Remove all the screws and drill a 1W' hole V16" deep into the top of P and }"i6" deep into the bottom ofQ. then clamp P to the top ofN-O. ELEVATION CONTROL 71 . 0. Apply glue to the mating surfaces of Nand 0. 3. and screw the pieces together. preventing changes in the height of the feed table caused by sanding vibrations. 3/8" deep Yo" hole Y:. Disassemble the pieces. Install the carriage bolt and attach the washer and wing nut. stopping it from turning with the rod.. cut the rabbet and slot in the top and back side of N as shown in the Front and Side views of the Elevation Control Drawing.Construct the elevation control 1.4" screws through the top of Q and W' in P. and allow the glue to dry.

glue and fasten Q to the N-O-P assembly. Set the shaft assembly in place on the stand. Drill Yz" holes completely through both Gs. Using the two previously drilled W' holes in Q as guides. secure the motor mount to part I. clamp them together with three bar clamps. Bolt the pillow blocks to the stand.18" hole in the center of each. drill pilot holes.:4" squares from 3. Cut the motor mount block (U) to size. 2. With a rabbeting bit. page 71. Attach them to the hood assembly with machine screws. Attach the 2" pulley to the motor shaft. Make the dust hood 1. Secure the handle on the threaded rod with a 3.:4" screws. With the nut in place.:4" from the right-hand end. below. Slip S over the rod and crank up the rod into contact with the feed table. Drill pilot holes through the pipe and into each V where shown in the Exploded View Drawing. and mark the mounting holes for the threaded inserts on both Gs. Attach the stovepipe to V with #6 X 3. Drill a W' hole in a piece of scrap plywood 1Yz" from one edge. Tighten the nuts to hold the handle firmly in position at the bottom of the threaded rod. and place a 5At dowel 2" long in the hole. 4. starting 13. Cut the dust hood ends (V) to shape as dimensioned in the Dust Hood End Drawing.) 3. Clamp the motor to the mounting block.$_'_("'%) POWERTOOLSAND ACCESSORIES THICKNESS SANDER continued 8. page 68. then. page 71 (the shape of the pillow block used will determine the inside shape). cut Y to fit the shape of the hood. Cut the handle (R) to size and shape. Center the pillow blocks on G. Center the sanding drum over the feed table..:4" nut above and below the handle. and the nuts on the bottom of the machine bolts.:4" diameter as shown in photo A. Cut part Y to size. Construct and mount the drum 1. then cut. rout a ¥a" rabbet 3/8" deep around the semicircular inside top edges of V. and install two # lOX 1 Y2" screws where shown on the Exploded View Drawing. (If you like. and mark the mounting-hole locations.R!~ . clamp it in place. and position the drive belt to align the pulleys. 72 . stop-collar setscrews. yet it prevents fingers from getting too close to the abrasive action.. 10. the center of the dowel I?/s" from the blade. Screw the adapter to Y and screw Y to the hood from the inside of the hood with #6 Xl" roundhead wood screws. drill like-sized holes through the front rail. Once all the discs are on the rod. Align S squarely with the bottom of the table. Drill two W' holes through Q where indicated for later mounting to the front rail (H). Position the elevationcontrol assembly where shown on the Front View and Side View drawings. Insert the 12" threaded rod through N-O. 5. and bolt the motor to U. Fit the squares one at a time onto the jig. Round over the outside corners with a V<i" bit. Slip the 5" pulley onto the left end of the drum shaft.:4" plywood. and insert the ends of the shaft into the pillow blocks. Clamp the jig to the bed of your bandsaw with 2. and clamp it in place. 12. mark diagonals to find the center. Position the hood over the pillow blocks. 11. and attach the hinge to it. Drill the 3/a" motor-mounting holes. Cut a 17W' length of 6"diameter stovepipe in half lengthwise. 9. Bolt the elevation control to the rail. 3. then drill a ¥<I" hole through its center. and instal1 the four threaded inserts. Drill and countersink W' holes where indicated for later mounting of V to the stand. Cut the maple strip (W) and acrylic strip (X) to size. 5. Rough up the 'Va" steel shaft with a file. use 6" PVC pipe in place of the stovepipe. and cut the 18 discs (T) to 33. Drill the holes on the marks. a 4if hole through it and the stovepipe hood to match the diameter of the vacuum-hose adapter. _A-_. and drill a 1W' hole W' deep on the bottom of the Yz" hole to house the ¥<I" nut. 4. Locate the center of Sand drill a 1" hole through it. epoxy the discs to each other and to the shaft. Rip and crosscut eighteen 33. Cut the rod-tip holder (S) to size. 6. clamp them in position. Tighten the pulley setscrew. and drill a 5. Remove the clamps and the pillow block/drum assembly. Using a bandsaw. The acrylic provides a clear view of the sanding.. page 68. and thread it through the nut in place in P.

Instructions for adhering the mat to the sanding drum and the sandpaper to the mat are included with each order. pushing the material on through the sander using the pushblock as shown in the Pushblock Drawing. below. Attach this to another piece of plywood or particleboard the same width as the feed table (12"). from Shopsmith. or call 215/94S·0400. Dept. and again raise an eighth of a turn and sand to the desired thickness or smoothness. Unlock the elevation control and raise the table by turning the handle no more than an eighth of a turn at a time. 3 X 77". Contact ANIT. Davton. 120-. A526. 73 . Va" bore with stop collars. below. Rigid-mount VPLE series. then plug the cord running from the switch into an outlet. then lock the elevation control. Repeat step 2. 2350 Hubbell Ave. Instructions for attaching the Velcro mat and sandpaper included. 2. OH 45414. Felt-backed sandpaper. Raise the table so that the bottom of the drum just touches the top of the material to be sanded. PUSHBLOCK Buying Guide • Two vacuum-hose adapters. Relock the elevation control. Plug the motor into the powersupply switch.O. Des Moines. Contact Woodmaster Tools. Run a hose from your vacuum to the vacuum-hose adapter on the dust hood. grits range from 40 to 220. See the Buying Guide for our source of Velcro mat and sandpaper strip. and 150-gritpaper. Connect the power supply switch to the front of the stand assembly. and slowly feed the sanding board under the drum as shown in photo B. MO 64108.6. attach two sheets of 60· grit sandpaper to a piece of 3. contact Standard Bearings. Or call 800-S21·6651 or 816/756-2195. or callSOO-554-S123 or 515/265·5261. Forprogressively smoother finishes. Box 70. 516262. • Ball-bearing pillow blocks. IA 50317. Continue to sand and raise the feed table with the elevation control until the sanding drum is uniformly round over its entire length. WDS. catalog no. P. Kansas City. Call SOO·543· 7586 or 513/S9S·6070 for price. Catalog no.. Turn on the sander and vacuum. for current price. Using the thickness sander 1. Royersford. For the current price. Sand all remaining wood surfaces and apply the finish of your choice. Part no. • Power switch. Sand the drum to size 1. Velcro mat.. . 2. 3931 Image Dr.4" plywood 13W' wide by 12" long. PA 19468. • Velcro mat and sandpaper strip. (This sanding ensures that the sanding drum is parallel with the feed table.) 3. Note: Use 60· and 80-grit paper on the drum to remove unevenness remaining after resawing or for thickness sanding. Using contact cement or spray·on adhesive. Raise the feed table until the sanding board just makes contact with the laminated drum. Slowly and steadily feed the material from the front side only. Hole for hanging Caution: Feed the sanding board through from the front side only. 1SVMW. 2908 Oak. use 100·. 3 X 77".

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