I'd like to be able to make parts identical to a template, like you
would using a router and flush cut trimming bit, only I want to do it
on an Oscillating Spindle Sander. I figure I'll have to bandsaw
roughly to shape anyhow, and with a solid OSS I can both finish the
piece to size and have it sanded smooth in one step.
On the drill press I've seen a disk that goes below the sanding drum
that guides the template. However, on an OSS the spindle goes up and
down into the table. Where and how can I mount a 1/4" diameter disk
with which to guide my template? Maybe I just haven't thought it
Well, the simplistic answer is to make the template 5/16"
or so smaller in dimension than the finished piece size. Then, mount
the work piece on the template, and, place the pin RIGHT next to the
Alternatively, simply use the template to mark an outline
on the work piece, and, free-hand it. Should be easy enough to do
with an OSS. If you need a couple of pieces to be "identical", then
stack them up and sand them to final size at the same time.
Woodcraft sells a sanding drum that has a large wooden "bearing"
that does what you're looking for. Check it out. The bearing was
a little too undersized for my taste and I replaced it with one
that I made via trial-and-error with a circle cutter.
Having said that, doing template work with a sander is the *LAST*
thing that you probably want to do. It's like scrubbing your
kitched floor with a toothbrush. I make solid body guitar bodies
from templates all of the time and wouldn't consider doing it
with my OSS or drill press alone. Here's what I recommend (and use myself):
1) Go to Woodcraft and ask for a Whiteside solid carbide spiral
flush trim bit with bearing. Don't go with the standard straight
flush trim bits, even though they're cheaper, especially if your
template pieces are thicker than 1/2". Routing thick template
pieces by hand on a router table with regular straight bits
is *dangerous*, especially when you hit places where the grain
changes direction radically. The solid carbide spirals w/bearing
are pricey but they're a bargain compared to the cost of new fingers.
Spiral cutters also eliminate chatter and give you a very smooth
2) Mount the template to the piece and and bandsaw as close to the
template line as possible.
3) Route using the template and spiral bit on the router table.
4) Clean up anything needing cleanup on the OSS.
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