A small disk sander is a useful and cheap addition to the shop. For about $100, you can buy a cheap combination 6″ disk/belt sander that’s extremely useful. The size and cost of power tools does not scale linearly, and if you want a big disk sander you might as well make your own.
The motor for this build is a 1kW single phase motor pulled from a floor polisher found in the trash. That’s enough to push a sanding disk around, but when you get to tools this large, you need a good base, good tilt mechanism, and everything should be extremely heavy.
This build meets all those requirements while still using mostly recycled components. The work table is actually made of three pieces of recycled aluminum epoxied together. Yes, you should cringe at this, but it actually makes a little bit of sense: thinner pieces can be cut on a table saw, and if you’re extremely careful during the glue-up, you can cut the mitre slot without a mill. This frame attaches to a frame made from aluminum extrusion and filled with a homebrew epoxy granite mix. Remember, heavy is better here.
In keeping with making a huge disk sander out of stuff pulled out of the trash, the trunnions and motor hub were cast out of aluminum melted in an old propane tank furnace. Once these were cleaned up, a disk was mounted on the hub and trued up in the most unsafe manner possible.
With a few additions including a machined mitre gauge, dust collector, and legs made out of wood that’s far too pretty for a simple shop tool, this huge assemblage of trash turned out to be a great sander. You can see a few videos of it below.
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