Need advice for building drum sander

[Poobah]

Folks,

I'm building my own drum sander (like the Flatmaster from Stockroomsupply for example). There is one thing I don't fully understand yet. What kind of rod should I get for the drum and where can I buy it? Lowe's and HD have a very meager selection if anything in 5/8" and I don't really know what kind of metal I need for this application.

I've got a 1HP motor, 1750 rpm from Grizzley and few pulleys and such and was going to make the rotor out of multiple 4 inch diameter MDF discs.

Is there some kind of special glue to bond wood to metal or do I use a threaded rod?

And finally, if all I can get at the big box store is a 3ft rod, any tips on cutting it to size? I imagine my dremel isn't up to the task and the jig saw even with my metal cutting blade would be rough. Do I need one of those 4 inch grinder/cut-off tools or maybe that dual blade cutoff saw conveniently on sale at HF this week for $60.00 on Black Friday?

[Stytooner]

It depends on the design of course as to what material to use for the bar.
All thread might be a good choice to compress the discs, but I think epoxy would work well too, provided you roughed up the surface of the bar. That makes it less easy to disassemble and repair, but might be more balanced that the threaded rod approach.
There is a link where I like to get small quantities of metal.
http://www.speedymetals.com/

You can buy the bar in standard lengths or they will cut exactly what you need.

The old tried and true hack saw works fine for bar and threaded rod. I do have one, but can't tell you the last time I actually used it.
I have two steel cutting bandsaws, a jig saw setup for cutting steel, a plasma cutter, grinders, etc. My hacksaw is a lonesome tool in my shop, bless it's little heart.

[pecker]

Your rod needs to spin in a pair of pillow block bearings, so threaded rod might not work.

Your 4" discs only need to be glued to each other, not the shaft. You could use 2 collars that clamp on the shaft and have a flange that could be screwed to the drum of mdf.

[dbhost]

I am in the process of building one myself. A very slow, and painful process as other projects have taken priority...

My design, is probably overkill, but here goes nothing. The rod is planned to be 3/4" smooth steel rod ordered from Amazon

3/4" bore pillow block bearings from Amazon unless someone can clue me into better bearings that won't run me into the poor house.

3/4" shaft pulley. I plan on getting a keyway cut into the smooth rod by a local machinist for a machine key. Probably go with a 1:00-1:00 ratio, like a 3" pulley to 3" pulley. I need to scrape the rust off my head first. And figure out the speed of my HF motor. My plan is to pull the 1 HP motor out of my HF band saw, replace that with a 1.5 HP motor, and use the HF motor for the sander...

I started out cutting 3" disks out of MDF, but did NOT like the way they are coming out. So I am swapping over, getting some nice big, and deep hole saws, and my latest idea is 4 1/8", out of jointed / planed 2x stock. I plan on gluing it up in sections, chucking it in the lathe with a jacobs chuck on the other end and boring the through hole in segments. Then run the rod, and the segments together. Probably use Epoxy... Once that is all done, install it and flatten / true the drum in place...

My biggest problem is I want to build a cantilevered 18/36 sander, which means LOTS of quality time with metalworking friends... Sure wish I had the equipment to do that work!

[Stytooner]

Here is where I buy pillow block and flanged bearings. Great selection and prices. High quality stuff.
http://www.surpluscenter.com/sort.as...s&keyword=PBPB


This is nice rod here.
Turned, ground, polished and stress relieved.
http://www.speedymetals.com/pc-1557-...d-000-001.aspx

Stress relieved cold rolded.
http://www.speedymetals.com/pc-1584-...-finished.aspx

Good prices for quality materials.
Post some project logs, guys. Love to see them.

[Poobah]

Wow, great idea with the collars. Thanks.

Also thanks for the link to the round bars. That gave me the right words to find this on Amazon:

http://www.amazon.com/Stainless-Prec...2005043&sr=8-4

Amazingly this is cheaper than the identical bar in a 36" length. Add in $3.99 for next day shipping with Amazon Prime and it's hard to beat. Will have to cut it down to size ... guess that means buying a new tool ...

Now my imagination has run wild and I'll try to add a thickness sander component after I've built the basic sander. The basic sander is supposed to mount in my mobile saw base and be able to use the rails for fences and hold downs as well as the whole table top for large pieces.

[toolguy1000]

shopnotes magazine has offered plans for both of those tools over the past 4 years.

[Mr__Bill]

Locally an auto parts store carries steel rod, it's kind of expensive compared to the steel supply house but it's 130 miles closer for me. A large lumber yard may also carry it. Just remember to check for straight.

Bill

[LCHIEN]

good luck cutting that stainless steel rod with a hacksaw. I'm sure you can cut it but I'm predicting it will be long hard slow work.
Steel, brass or aluminum would be cheaper (by about a third) and *much* easier to machine/cut...? Is there a reason for stainless other than being the best you can buy? I see them all at amazon http://www.amazon.com/s/ref=nb_sb_no...OD+rod&x=0&y=0

[dbhost]

Stainless smooth rod is reasonably easily cut with a jig saw and a Rem Grit blade. Just cut it a bit proud and clean up the end with a bench grinder if you have to...