Smooth Wooden Wheels & Circles with a Drill Press Sanding Jig
Making wooden toys often means cutting a lot of small wheels. A hole saw makes quick work of cutting them to size, but it usually leaves behind rough edges that need to be cleaned up.
Sanding each wheel by hand can be tedious, especially when you're making several identical pieces. And it's easy to end up with an uneven edge or a flat spot.
To make the job easier, I built a simple drill press sanding jig that uses a sanding drum to smooth the edges of wooden wheels and circles.
The jig holds the wheel on a pivoting arm, allowing you to bring it into contact with the sanding drum and rotate it for an even, consistent edge.
It's a handy setup for toy making and other woodworking projects that require smooth circular parts.
A Simple Jig for Sanding Wooden Wheels
The jig consists of an auxiliary drill press table with a pivoting arm.
A sanding drum mounted in the drill press does the sanding, while the arm supports the wooden wheel and controls its position.
The auxiliary table clamps securely to the drill press table.
A curved slot in the auxiliary table allows the arm to swing through a controlled arc, moving the wheel toward or away from the sanding drum.
At the end of the arm, a carriage bolt, washer, and star knob provide a simple way to mount the wheel.
The design is straightforward, but it makes sanding a batch of wooden wheels much easier.
How to Use the Drill Press Sanding Jig
Start by installing a sanding drum in the drill press and securing the auxiliary table.
Slip the wooden wheel over the carriage bolt on the pivoting arm.
Add the washer and star knob, then tighten the knob just enough to hold the wheel in place while allowing it to rotate freely.
With the wheel positioned away from the sanding drum, turn on the drill press at a speed appropriate for the sanding drum.
Slowly swing the arm toward the drum until the edge of the wheel makes light contact with the abrasive.
Then rotate the wheel against the sanding drum, keeping your fingers clear of the abrasive.
The important thing is to keep the wheel moving. If you hold one section against the drum too long, you'll sand a flat spot into the edge.
Use light pressure and make several passes rather than trying to remove all the rough material at once.
Continue rotating the wheel until the entire edge is smooth and even.
Consistent Results for Wooden Toys and Other Projects
This jig is especially handy when you're making several wheels of the same diameter.
Once the arm is positioned, you can sand one wheel after another using the same setup.
The sanding drum removes the rough edges left by the hole saw, while the pivoting arm helps maintain a consistent position.
It's also useful for smoothing other circular wooden parts, such as decorative discs and small round components.
For the best results, start with wheels that have accurately centered holes and use a sanding drum that's in good condition.
And because sanding generates fine dust, use suitable dust collection and eye protection.
A Handy Addition to Your Drill Press
A drill press is already one of the most versatile machines in a woodworking shop, and this simple jig gives it another useful job.
With an auxiliary table, a pivoting arm, and a few pieces of hardware, you can turn rough wooden wheels into smooth, consistent circles without spending a lot of time sanding by hand.
If you make wooden toys or other projects with round parts, this is one shop-made accessory that's worth keeping close at hand.
More Woodworking Tips & Tricks
A clever jig can turn a frustrating task into a quick, repeatable operation. Discover more practical woodworking tips, shop-made accessories, and easy techniques that help you get better results from the tools you already own.
From drill press upgrades to sanding tricks and useful workholding solutions, these ideas can make your time in the shop more productive.
EXPLORE MORE WOODWORKING TIPS → Simple Jigs and Shop Solutions for Better Woodworking
