DIY Thickness Sander

Turn an ordinary belt sander into a thickness sander.

You can make a simple thickness sander using a belt sander and some strips of lumber. The problem typically experienced with most DIY thickness sanding using hand-held belt sanders occurs when trying to control thickness. The tendency is to tip them sideways or sand too deep. But you can control the thickness by placing hardwood strips alongside the workpiece. When the sander reaches the strips on both sides, the thickness of the workpiece is consistent between the strips. Start out by making a thickness sander set at 1/2-inch.

Things You'll Need

• Fir plywood, 3/4-by-24-by-24-inches
• Hardwood panel, 9/16-by-18-by-22-inches
• Maple strips, 1/2-by-3/4-by-24-inches
• Cordless drill
• Drill bit, 3/16-inch
• Wood screws
• Maple blocks, 1/2-by-3/4-by-2-inch
• Belt sander with 100-grit belt

Instructions

1. Place the fir plywood on a worktable. Place the hardwood panel in the center of the plywood. Place one of the strips flush against both sides of the panel.

2. Drill one hole in each end of both strips with a cordless drill using a 3/16-inch drill bit. Place screws in the holes and screw the strips to the top of the table. Drill one hole in each of the 1/2-by-3/4-by-2-inch blocks and screw them to the fir plywood on each end of the panel.

3. Place the belt sander with 100-grit belt on the panel. Hang on to both handles and pull the trigger to turn on the sander. Begin sanding forward and back moving parallel with the grain. Use a slightly oval shaped sanding pattern so that you can sand over the panel completely from side to side, sanding it down evenly as possible.

4. Sand with deliberate even motions, keeping the sander as level as possible. Watch as you pass over the strips. If the sander begins to make scratches on the strips, move away from that area.

5. Sand the panel until it is flush with the top of the sticks. Watch the strips to know when the thickness is correct.

Tips & Warnings

• If you have trouble realizing when the panel is the right thickness, smear some stain on the strips. When the stain begins to get sanded off, the panel is the right thickness.

• You can make thickness sander jigs any width or height. For sanding bulk material, use a heavy grit belt, such as 60 or 80 grit, to remove material faster.

• Wear safety glasses. Be careful with belt sanders. They have exposed edges that can cut bare skin.