Making a Drum Sander – Part 1 – Base

How the time flies – it is two years since I wrote a series of blog posts „Showing off my wood“ where I have shown various woods at my disposal for crafting. I have so much material in fact that it is not improbable but downright impossible for me to use it all up making knife handles and knife blocks, I just cannot make that many different knives alone. So I would like to make some high-quality end-grain cutting boards to convert at least some of that massive amount of material into something useful.

I started last year but I hit a snag. I need to mate wooden surfaces together perfectly, but there is no convenient way for me to flatten wooden surfaces in reasonable time and in scale. My manual method is precise, but also tiring and time-consuming. I need a drum sander to make even a few end-grain cutting boards. And I cannot buy one for two reasons. Firstly I don’t have the money. Second, I don’t have the space needed for one.

But since I have managed to build myself a belt sander, I decided this year to spend some time trying to build a drum sander too. I had more than a year to think about it and with the money these things cost, even if I spend a whole month building one, it would still be worth it.

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I started by gluing three large pieces of black locust wood together to form a large prism through whose center I put a 10 mm threaded rod. I cut the edges off on a circular saw and then I stood in front of a bit of a problem – how to turn a large-ish wooden cylinder without a lathe. I rigged up a temporary wooden structure that allowed me to span the prism in such a way that it could run against the edge of the circular saw whilst being continuously rotated with hand-held akku drill. I hope the picture makes it clear what I mean.

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It made an absolutely unholy mess and I was terrified the whole time but I succeeded in making a rough cylinder round enough to progress to other works. I will make the cylinder perfectly round and concentric with its rotational axis later.

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I swapped the threaded shaft for a smooth 10 mm one and to secure it to the cylinder I drilled 3 mm holes throughout it and the shaft on both ends and I drove 3 mm hard steel through the hole. I hope it’s strong enough for the forces needed, if not and it shears off during work, I will have to think up something better. I also cut grooves in the shafts to secure one ball bearing on each side with circlips. I later decided to use two ball bearings, with the second one being put near the first one and not being secured with circlips. As you can clearly see, I am making things up as I go along and I do not always know what I am doing.

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A 15 mm particle board from an old PC table serves as a base to build upon. To hold the ball bearings I cut short boards from hardwood (beech) and I made cutouts for the ball bearings between two pieces and screwed them together with long wood screws. It appeared to be reasonably strong and it held the ball bearings firmly, but it was a bit wobbly. So I glued 15 mm particle boards to the beech boards to widen the bases a bit.

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While the glue was setting on that, I trimmed the edges of the cylinder. I used the boards that held it in the circular saw jig and a hand-held drill as the source of rotation again. That left me with only one hand free to trim the edges but a hacksaw blade proved to be quite efficient at that. Setting the initial groove was a bit fiddly but once started, it went easily, albeit slowly. The edges are not perfectly square and flat but they do not need to be.

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Once the boards for holding the ball bearings were glued together, I glued them to the base with five-minute epoxy. Epoxy is expensive, but I needed a strong bond to make subsequent works easier.

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Once the epoxy cured, I added 4 80 mm wood screws through the beech cores and then also multiple 6 mm bamboo dowels glued in with PVA glue. I do hope that is strong enough in itself but it was additionally reinforced with the last step.

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 There are strong anchor points on the base for the ball bearings and I changed the way they are held between the boards from the temporary wood screws to the final solution – I put two M8 rods through the whole thing with pronged nuts hammered into the particle board base and wing nuts on top. It holds the ball bearings firmly in place and the cylinder can rotate freely.

And this is where I am right now. Next, I can start working on the propulsion part.

During all this work I am also spending a lot of time just thinking not only about each step but also about what might be the main challenge of this project – the adjustable sanding thickness. I have several ideas but they all are fiddly and complicated and I would like to keep things as simple as possible. The simpler the mechanism, the fewer potential points of failure. I won’t even attempt to make some sort of automatic feeding – the wood will be fed through the machine manually (if I manage to make it work).

I Don’t Need No Gym

I am doing my best to publish at least one article a week on my knife blogge, but I had trouble managing that and I could not write much for Affinity as you might have noticed. The main reason is my huge garden, which kept me occupied for two months almost continuously.

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Whilst re-potting my bonsai, I tried this year also to plant new poplar trees in my coppice since the water voles did such a number on them a few years ago. I found an easy way this time to plant them -instead of digging holes, I drilled them with a long carbide-tipped 12 mm masonry drill. It went comparatively easy and fast and after just a few days work I managed to plant several rows of trees. Then came warm weather and everything started to grow, the trees took root and it looked promising. And after that came abnormally deep frost (-5°C) most of the trees died and my work was thus wasted. The frost also killed one of my most beautiful outdoor bonsai trees – my only hornbeam – the roots froze in the bowl. What a beautiful spring start!

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I did manage to get about 2 cubic meters of firewood from my coppice this year, which is good, about a month’s worth of heating right there, with minimal money expenditure. I also cut a lot of dead wood from my apple tree, which is slowly dying from water vole damage. The tree still lives, but only just. The odds are that next year it will all be firewood since it also received additional damage from the late frost. What a beautiful spring start!

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When planting potatoes this year, I added a lot of charcoal to the soil that I prepared over winter. Then I covered the potatoes with only a thin layer of soil and a thick layer of grass clippings to try at a larger scale the experiment from last year. After that came a short drought and abnormally high winds, which blew the grass away in some parts, and the potatoes froze due to the strong late frost that followed shortly after. About 10 % of the potato patch thus did not sprout at all and another 10% look weak and sickly even now. What a beautiful spring start!

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Here used to be several huge compost heaps. I flattened them out into one huge new patch, which took me several weeks of hard work. I planted pumpkins on there after the strong frost was over. But the weather after that was so cold and miserable that they did not grow at all for about a month and slugs destroyed about half of them despite my best efforts, using both manual and chemical tools at my disposal to kill those buggers. On some evenings I collected as much as about 1kg of slugs from the vegetable patches. This week some of the pumpkins finally started to grow as the night temperatures are over 10°C at last, but some are still tiny and there is a huge question mark over whether I will or will not have any use from all this work at all. What a beautiful spring start!

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The seeding potatoes were very small and thus there was more of them than I expected. I had to prepare a small new patch near my second greenhouse to plant them. It was a lot of work to haul all that compost there to plant them, but at least these were completely unaffected by the frost and they appear to thrive. Great! When I was at it, I also prepared a second patch, where I planted red beets. Those are still tiny because the weather was so fucking cold overnight that it was on some days in June colder than it was first two weeks in April. I also planted some sweet corn, two packets. One packet did not germinate at all, and the other one produced just several sickly plants that are now still smaller than the grass that I have not mown for a week. Fuck this spring.

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I had so many tomato seedlings that I planted over twenty of them outside. Three got immediately mauled to death by slugs. The rest managed to grow tough enough for the slugs no longer trying to eat them but they did not grow any taller – they are positively tiny. Because the nights were so cold. I am curious if we get an extremely hot and dry summer after the extremely wet and cold spring. So, like last year, first nothing grows because it is too cold, and subsequently nothing grows because it is too hot. I hate this year’s weather.

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I did not sift the compost heaps but I did at least pick bigger stones manually, as I do all year throughout my vegetable patches. I got several buckets worth. If you remember, I used most of these accumulated stones last year to repair the walking path to my home. Well, I got about 20% of what I used up last year back again. Stones are not a renewable resource, but my garden has a seemingly unlimited supply of them.

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When planting the trees, I hit something hard twice. Once a bigger stone and once a buried brick. And when planting beans and working on the compost heaps I suddenly hit a really large stone, that I subsequently had to dig out. These are big slabs of phyllite that were used as paving stones in the past around here. I have a pile of them both from digging them up in my garden in seemingly random places and from the time when we too had walking paths paved with them, which I replaced with modern concrete paving a few years ago. At least these stones can be useful in the garden, but hitting one with a gardening fork or a shovel is not fun. Neither is hauling them solo onto the wheelbarrow. I procrastinate moving this one for three weeks because I sprained my back with the previous one.

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Apart from slugs, grass also thrives in the fucking cold weather. I have to mow it to be able to access all the areas of my garden where I need to work. At least there are no HOAs here so when I want to leave a patch with pretty flowers on it where it does not impede me, I can do that. So I do. Yay for pretty flowers!

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Tomatoes inside the greenhouse do look promising this year. I put a lot of compost and some fertilizer in there in the fall and I mixed it with the soil thoroughly. Inside the greenhouse, the climate was warm enough, albeit possibly too humid. The plants had wet leaves each morning because they had to actively pump out water. I used a chemical spray to prevent Phytophthora infestans. I hope it works because if they do not get sick, they really do look promising. Fingers crossed, I had enough setbacks this year already, and I need some wins.

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The fig trees are growing like mad. I cut them down to about 70-90 cm in height and they are double that already. They were overshadowing the tomatoes and I had to prune them. They put out some fruit already, so I might get some this year too despite the really heavy pruning in early spring. The figs really liked the warm and tepid winter and the greenhouse shielded them from the negative impacts of the cold spring, so they are the only plants that truly thrive. The grapes and pomegranates thrive too, but I did not take pictures of those since I have been ranting long enough already.

Often in the past, I said that I do not need to go to the gym, I get enough workouts in the garden and it is more useful. Well, this year the bad weather and extreme slug infestation are doing their best to make the second part of that statement untrue. At least I don’t have to pay for it. Oh wait, I do pay for it – the molluscicides, fungicides, and seeds…  Well, I might still come out with a profit, but it is not sure. I need at least 150 kg of potatoes to come even. Every other vegetable on top of that would be a bonus. That is not impossible, even with this bad start of the year.

A Jack of all trades is thicker than water

This is just a small post about sayings that are now abbreviated and have come to mean the opposite of their original meaning. Much like the poor word literally, which leaves me a bit unsure about how to express that I actually mean literally literally, not figuratively literally.

First one is “The customer is always right”. Especially in the US this has taken on a meaning of customers being allowed to abuse staff and make their life as difficult as possible, when it’s actually “the customer is always right in matters of taste”. They want a strawberry mustard cake? You bake it. They think that pink and green make a lovely facade? Let them have it. It doesn’t mean that they get to return a meal they ordered just because they don’t like the plating.

Second one is a “Jack of all trades, but master of none”. It’s used to dismiss people with a broad field of knowledge, but no real speciality. The actual quote is “a Jack of all trades is a master of none, but often times better than a master of one”. What use is a plumber when your electricity is broken? What use is a car mechanic when you need help in the garden? That’s not to dismiss specialists, but it also means that often a broadly educated and versatile person will be more useful.

An last but not least, the ever favourite “Blood is thicker than water”. The full quote is that “The blood of the covenant is thicker than the water of the womb”, meaning the exact opposite of the common understanding that blood family is the most important. Most important are your chosen relationships, not those you acquired through birth.

What other sayings come to your mind that have changed?

A Soaring Eagle Knife

In a sense, this knife was in the making for over twenty years. At least more than twenty years ago I drew the picture of a soaring eagle for the purpose of using it to adorn a knife. Initially, I wanted to etch the image on the blade, but I made this blade with a ridge, thus it could not be fitted on it. So I decided to use it on the leather sheath instead.

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The blade is mirror-polished and it was a major PITA to take a picture. One day I will simply have to invest time and money in a better lighting setup. I just don’t want to.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

The handle is made from the same material as the kestrel knife, but the inserts are only from a birch polypore. The big thick white pieces contrast nicely with the wood. Which has in my opinion a much more interesting pattern than the previous one.

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© Charly, all rights reserved. Click for full size.

To take a picture of the embossed sheath was a bugger too. It is too shiny and in most pictures, it gleamed like a naked bum. At some point I had to work with what I had, I could not re-take the photos forever.

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© Charly, all rights reserved. Click for full size.

Carving and embossing all the feathers was fairly difficult, especially the tips of the wings, and I am sure it could be done better. Sometimes I think I am punishing myself with these elaborate designs. But despite its flaws, this time I do like the end result. I think it looks handmade, but not ineptly made.

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The metal fittings are from wire-brushed bronze and the washer at the end of the peened tang is shaped like a chrysanthemum blossom. It is already acquiring patina. I was thinking about whether to let it age naturally or whether to speed up the process and I decided to let things to their natural progression.

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With the blade over 17 cm long, it is a big boi. But weighing just about 392 g with sheath, it is not particularly heavy. And since the point of balance is at the forefinger just at the boundary between the white polypore and the wood of the handle, it feels very light and nimble in the hand.

A Kestrel Knife

I’ve been extremely busy these last few months, that is, I was busy when I had the spoons and the strength to do anything meaningful at all. Knifemaking has progressed at a snail’s pace, which those who read the knife blogge will know. But I did manage to finish dressing up two more blades from my first overabladeance and today I sharpened them and I started to take pictures. And I started with the smaller of the two.

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© Charly, all rights reserved. Click for full size.

I tried my hand at embossing the sheath with a picture of a kestrel, based on one of my own photographs. I do not think I have done a spectacular job, but I showed it to a few people IRL who seemed to like it. Although some thought the kestrel was an eagle. But I think that is an indictment of their knowledge of birds and not of my leather carving ability. Though honestly, I had trouble getting into the mindset needed to work, I am barely keeping depression from eating my brain.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

The blade is an old design that I have shown here multiple times. Nothing new about that, but I tried some new materials for the handle and I think they show great promise for future projects.

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© Charly, all rights reserved. Click for full size.

I used strongly decomposed (spalted) wood and this time, I submerged the wood in wood dye first and then I stabilized it with a resin that cures at 80°C. And it worked very well. The dye soaked primarily into the more decomposed parts and that created an additional marbling effect to the one created by the fungus itself. The white-ish inserts are not bone this time, but also resin-stabilized material – birch polypore, Fomitopsis betulina. It looks to be very promising material, I will write about it more when making my next project with it. And the chocolate brown inserts are also resin stabilized conk – tinder fungus, Fomes fomentarius. That also looks like a promising material for bolsters, inserts, etc.

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And to cap it off, at the end of the tang is a nut shaped like a heraldic rose blossom.

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Sometime this week I will also make pictures of the second knife. That one is significantly bigger.