Sanding drums larger than % inch in diameter are too large to fit through the hole in most drill press tables. To make full use of the sanding surface of larger drums, build a table like the one shown above. Use a coping saw, a saber saw, or an electric
drill fitted with a hole saw to cut a hole in the plywood top, centering the opening 3 inches from the back of the table. Screw the L-shaped base pieces together from l-by-3 and 2-by-2 stock (above, right), then glue them to the table.
Sanding curved stock
Clamp the jig base to the drill press table with the hole directly underneath the drum. Adjust the table height to bring the bottom of the sanding sleeve level with the jig. Holding the workpiece firmly, feed it at a uniform speed in a direction opposite the rotation of the sanding drum (right). To avoid burning or gouging the workpiece, feed it with a smooth, continuous motion. As segments of the sanding sleeve wear out, raise the drill press table to bring a fresh surface to bear.
1 Building the table
The simple jig shown at right will enable you to sand thin stock on your radial arm saw. Cut the table and fence from %-inch plywood, sizing the pieces to fit your saw. Cut a slot out of one edge of the table large enough to accommodate the sanding drum you will use and allow you to shift the drum forward and back for different sized stock. Rout a %-inch-wide groove along the length of the fence, leaving % inch of stock below the channel to slip into the saw table’s fence slot. Insert the slotted edge of the table into the groove in the fence and screw the two pieces together.