New power finger file.

https://www.youtube.com/watch?v=OUm1D7hdt50

I wanted to use aluminum for this project, 10mm thick would have done the job but I had no idea where to souurce that size sheet from; however, I did have some sheets of 25 mm Delrin so I thought I'd have a bit of a play with that medium.

Delrin turns nicely giving a nice finish, but when grinding and filing the finish is quite rough. I expect some more work in this area to neaten the project up a little.

I cut a rough shape from a largish slab and set about shaping it with a finger file. The hole for the motor was turned on the lathe, this necessitated making the handle a little shorter than I'd like. As it turned out the handle fits the hand quite comfortably. I cut a slot just forward of the handle and tapped a hole from the top of the blank for clamping the motor in place. Next I mounted a small piece of Delrin in the four jaw and drilled a 10mm hole for the front wheel mount. After mounting the motor, I spun up a small piece of Delrin and sunk it into the drive drum and pushed the drum on the splined motor shaft. I was going to use some Delrin for the drum but thought it might melt so used a stell drum mounted on a Delrin Bush.

For the motor cover I turned a 12 mm thick piece of Delrin to fit over the motor and then turned down a piece of PVC to slide over that. The end is capped with another piece of Delrin I had lying about, yellow unfortunately. I mounted the swich in that.

The unit works nicely, but curiously the 18 volt motor I sourced from an old cordless impact driver smokes badly when run on 18 volts. On 12 volts it runs ok, if a little hot.

Nice build. Extra kudos from building whole new tool, instead of using angle grinder etc.. as a powersource.

that looks like a good project to 3D print the frame.:idea:
Thanks for the project. Nice job

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Thanks th62! We've added your Handheld Power Sander to our Sanding category,
as well as to your builder page: th62's Homemade Tools. Your receipt:

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="http://www.homemadetools.net/homemade-handheld-power-sander"> <img src="/uploads/213170/homemade-handheld-power-sander.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="http://www.homemadetools.net/homemade-handheld-power-sander">Handheld Power Sander</a> <span> by <a href="http://www.homemadetools.net/builder/th62">th62</a></span> </div> <div class="tags">tags: <a href='http://www.homemadetools.net/tag/portable'>portable</a>, <a href='http://www.homemadetools.net/tag/belt-sander'>belt sander</a> </div> </div> </div> </div>
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