Sanding facets

[Wmcullen]

I'm not sure if this process is right or wrong; unique or common. But it works for me and I want to share in case it's interesting.​

17: Sanding facets with homemade drum for pens
last post:16-Facet-ilitating a New Project

Homemade sanding drums are well-known and easily made. I decided to make mine specific for pens by including 4 different levels of grit. It works well and gets the job done quickly.​

The Problem
When making a faceted pen with straight sides, sanding on a lathe becomes impractical.

My Solution
(Not rocket surgery, just how I did it.)
1. Cheap 2x4 pine cut and drilled with a 0.25" hole lengthwise.

2. Turned it round... no specific diameter... just round.

3. Installed a 5.5" long 0.25" bolt, washer and nut.
4. Cut a trench down the middle with a handsaw.

5. Shoved sandpaper into trench, wrapped around drum and cut so there was no overlap. Affixed with a small amount of glue.
Note: think through which direction the drum will spin before wrapping sandpaper.

6. The drum has 4 grits. Each facet can quickly hit each stop.
Note: Putting the segments on a bolt gave me much more control and accuracy than trying to hold the segment freehand.

Summary
I'm sure there are a billion methods to sand straight pen facets but I like the one I'm using and wanted to share.

Thanks for looking
- Cullen

 

[tgsponge1]

nicely done

 

[magpens]

@Wmcullen

Your "multi-faceted creativity" shines through again !!! .... This is a SUPER idea !!!!

Do you have a bearing on the lower end ? ..... enabling you to anchor/clamp the lower end and maintain vertical rigidity .....

I wonder if your "sanding drum" could be mounted horizontally on a lathe ..... I do not have a drill press.

BTW ..... how do you create the original faceted shape ..... do you do it on a mill of some sort ?

 

[Wmcullen]

I wonder if your "sanding drum" could be mounted horizontally on a lathe ..... I do not have a drill press.
BTW ..... how do you create the original faceted shape ..... do you do it on a mill of some sort ?

Thank Mal.
I don't have a bearing on the lower end of this drum but that would be a sound choice to make.
Mounting the drum horizontally on a lathe would have been a cleaner way to write this up. I didn't think of it but should have. Good call!
I made the original faceted shape on a router table using a new jig, which I'm still tinkering with like a mad scientist! Here's a link to the write up on it.
Best,
Cullen

 

[dogcatcher]

Slap some 40 grit on the drum and you can create the flats on round stock.

For making hexagon and pentagon shaped game calls I used a jig like the one on this video to fit my bandsaw and 2" upright belt sander.

First cut, trim with bandsaw, then sand on the belt sander with various grits.

 

[sorcerertd]

I'm guessing that Tuskan Raider didn't handle the sanding task well enough? I hear they are aggressive and hard to work with.

 

[Bryguy]

Great Tutorial. Thanks!