DIY Drill Press Drum Sander: A Simple Upgrade for Better Sanding
A drill press can do more than drill holes. With a sanding drum installed in the chuck, it becomes a handy tool for smoothing curved edges, shaping small parts, and sanding inside contours. It's an easy way to get more versatility from a tool you already have in your woodworking shop.
However, traditional drill press sanding drums have a few drawbacks. They can flex or wobble during use, and the drum often sits above the table surface, making it difficult to sand the entire edge of a workpiece.
This shop-made sanding drum upgrade solves both problems with a modified drill press table insert and a bronze bushing that supports the drum from below.
Why Upgrade a Drill Press Sanding Drum?
Standard sanding drums are typically supported only by the drill press chuck. Because the lower end of the drum is unsupported, even a small amount of runout or flex can affect sanding performance.
Another challenge is positioning the drum low enough to sand the full thickness of a workpiece. Depending on your drill press table, you may need an auxiliary surface or a special insert to provide clearance.
A shop-made insert with a recessed sanding drum addresses these issues while making the drill press more useful for sanding operations.
Build a Recessed Sanding Drum Table Insert
The foundation of this upgrade is a small auxiliary sanding table that fits into the replaceable insert opening of a drill press table.
A cleat on the underside matches the dimensions of the existing insert, allowing the sanding table to fit securely into position.
The sanding table provides a flat work surface while allowing the drum to extend below the tabletop. This makes it easier to sand the full edge of a workpiece without needing to raise it on a separate platform.
Add a Bronze Bushing to Stabilize the Drum
The feature that makes this setup especially useful is a bronze bushing installed in the sanding table insert.
Unlike a conventional sanding drum supported only by the chuck, this design uses a steel shaft that extends through the drum and into the bushing.
The upper end of the shaft is held in the drill press chuck, while the lower end rotates inside the bronze bushing.
This additional support helps reduce sideways movement and wobble as the drum spins, providing a more stable sanding setup.
The shaft and bushing need to be accurately aligned, with a suitable running fit, so the drum can rotate freely without binding.
Make Custom Sanding Drums with a Hole Saw
Another advantage of this design is that you can make sanding drums in different diameters to suit the work you're doing.
Start by cutting the drum blanks with a hole saw. A steel rod runs through the center of the drum and is secured with epoxy.
The rod serves as the sanding drum's shaft, extending far enough below the drum to engage the bronze bushing in the table insert.
After the epoxy cures, the drum can be fitted with sandpaper and installed in the drill press.
This approach allows you to make custom-sized drums for sanding a variety of curves and profiles.
A More Versatile Drill Press Sanding Setup
With the sanding drum installed, the upper end of the shaft is secured in the drill press chuck while the lower end seats in the bronze bushing.
The recessed table provides clearance around the drum, and the bushing helps stabilize it during operation.
Before sanding, make sure the insert is secured, the shaft rotates freely, and the drum doesn't contact the surrounding table. Use light sanding pressure and confirm that your drill press manufacturer permits sanding attachments and side-loading.
The result is a practical shop-made accessory that expands the capabilities of your drill press without requiring a dedicated spindle sander.
Whether you're smoothing curved furniture parts, sanding inside cutouts, or shaping small woodworking projects, this drill press sanding drum upgrade offers a convenient way to get more from your workshop equipment.
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