Poor mans Pattern Sander

[Troy D. Breeding]

I've been watching all the threads concerning the different styles of pattern sander with amazement.

Some are way above my pay grade. Others look like they would work, with limits.

Well after watching and wondering if I'm the only one that thinks outside the box I broke down and decided to show off mine. I've been using this style for years.

Simple and low cost. This is my third one over a twenty something years of using this design. Yea they will over time start to show wear and that's when I scrap the old one and build another.

If you have an osilating (sp) sander there is no need to remove anything. Just add this setup to it and go to work.

Here is the overview look:



At a slight angle for a better understanding:



As you can see it's about as simple as anyone can ask for. A piece of plywood and a PVC toilet flange. I routered out the plywood to except the flange. Then added a few screws to hold it in place. Afterwards I ground off the screw ends so that they wouldn't be in the way.

One thing to add. Before adding the screws, cut the pipe part of the flange to the desired length. I cut mine about 1/2" above the plywood. That's plenty for the edge of the gigs to rub against.

Next make sure to center the pipe an close as possible around the spindle drum. Then clamp in place until you feel good about it's placement.

Once I know it's right I then bolt it to the sander table.

After setting the gig on the attachment you can see that the piece to be sanded will need to extend past the edge of the gig approx. 1/2" to be able to touch the drum. Slightly more will allow for a clean cut.



All you have to do for the gig is decide how you want the sanded area it to look and sand it smooth. All I need to finish this gig is to add the toggle clamps for holding the material in place.

[Troy D. Breeding]

One thing I failed state. Recess the bolts that hold the plate to the sander into the plywood so that the bolt heads want be in your way.

[eagleone]

      thanks for posting that.  time to run to the hardware store!!!

[R. W. Mackey]

Very nice Troy, doesn't get much simpler than that. And even better is the cost.
 Thanks for sharing.

RW

[rmorris]

That is pretty cool Troy!

[monterey]

Finally, a method that even a tool nerd like me can do!

[ianpc]

Yes! Thanks for sharing this!

[BenBow]

Troy what size drum is that? Looks good

[Troy D. Breeding]

Ben,

That is a 3" dia. x 4-1/2" tall drum.

The beauty to all this is you can use different size drums.

However, the smaller the drum the more you have to extend the work piece beyond the gig.

[mwosborn]

I might be able to handle that one (maybe) - thanks Troy.

[mikkekeswick]

Great idea!
Thanks for posting that.

[monterey]

Ok, here is the dumb question!

Do the jigs need to cut from an offset of the 1/2" or to full size.  Can't get my brain around it.  :confused:

[Troy D. Breeding]

Mike,

If I'm understanding your question right the piece your grinding sets on the plywood gig you see setting on top of the plywood with the toilet flange attached. The piece that your grinding must extend out past the edge of the gig approx. 1/2" so it can reach the sanding drum. The edge of the gig rubs against the PVC pipe part of the toilet flange to prevent grinding off too much.

With a 4-1/2" drum you can sand the full face of any bow riser piece as the drum goes up and down. Just swing the piece back and forth along the length of the gig.

[Archer Dave]

Ah great idea. I think I have and old used toilet flange from a hospital job I did around here somewhere. Hehe, just kidding!   :D

[choochoou]

Toilet humor !

[monterey]

I did not phrase my question well.

Another way to say it: is the jig exactly the same size as the finished riser?

[Troy D. Breeding]

Yes, at least for me the gig is the same size as the finished riser. On an arc gig (like the one in the pictures) for putting in accent stripes in the riser it is. Now if your grinding a wave curve for footed riser you may have to play with the layout.

[monterey]

Thanks Troy.  Will be picking up materials next trip to the Depot.