04/17/2005
	Some notes on the drum sander project. (explanations of the
	pictures at END of file)
	
	Capacity: 35" wide by 8"-10" thick.
	
	Basic structure welded up from 2" square, 1/8"
	wall square tubing.
	Main Frame:
	Long Side Pieces : 37"	(4 needed)
	Short Side Pieces: 24"	(4 needed)
	Legs             : 48"	(4 needed)
	
	Top Frame:
	Short Side pieces: 24"	(2 needed)
	Long side pieces : 41"	(2 needed)
	
	I decided to make a separate frame to hold
	the drums, as it seemed that would make
	it easier to mount the drums and such.
	
	Conveyor Table:
	Welded up from 1 1/2", 1/8" square
	steel tubing.
	
	Long side pieces  : 48"	(2 needed)
	Short side pieces : 33" (4 needed)
	
	
	I was as careful as possible to keep the
	frame square and undistorted in the fabrication
	process, by assembling it on a known
	flat surface, and, by welding short beads
	on opposite sides of the tubes.  I had a small
	amount of heat distortion, but overall,
	very little trouble.
	I mounted one set of crosspieces about 24" down
	from the TOP end of the legs, and the second set
	about 40" down from the top end of the legs.
	(more exact measurements later)
	
	Things to do yet:
	Grind down and neaten up some of the welds.

	I need to dig up some 6" diameter, thick wall
	tubing (a couple of 36" pieces) for the drums
	I will then fabricate supports to hold them
	to the axles.  Probably will use 3/4" plywood
	and mill several disks.
	
	Finish building the conveyor belt tightening
	mechanism.  This will be a sub-frame that
	adjusts out from the main table, and is pushed
	by screws to tighten the belt.   The belt itself
	will probably be a 36 grit, cloth-back sanding
	belt.
	
	Finish building the brackets that attach the
	conveyor belt table to the height adjusting
	mechanism. (two done now, two more to cut out
	and fabricate).
	
	Fabricate the drive wheel mechanism for the chain drive
	that moves the four support rods.
	
	add the heavy duty castor mechanism for allowing
	this puppy to move easily.  I suspect I will use
	some large (10" or so) "Harbor Freight specials"
	I have kicking around on one end of the frame,
	with a smaller, steel castor on a pivot to allow
	it to raise and lower the frame on the other end.
	
	Cut 3/4" plywood panel that will sit on the lower
	frame, and provide a motor support for the drum
	drive motors.
	
	--------------------------------------
	DrumSander001.jpg
	Overall view of the base frame and top frame.
	
	DrumSander002.jpg
	Side View of base frame and top frame.   The
	tabs on the top frame are 1/8"x2"x4" (or so)
	welded in place.  They both provide alignment,
	and, a place for the attachment bolts.
	
	DrumSander003.jpg
	Head-on view of the top frame.   The little light
	patch on the left, long side is where I had to
	weld together two chunks of the frame steel to get
	a long enough piece.  More careful welding, running
	short beads on opposite sides kept things nice
	and straight.
	
	DrumSander004.jpg
	More or less straight on view of the conveyor belt
	table, leaning up against the old, lincoln buzz-box
	I am using to build it.
	
	DrumSander005.jpg
	Angled view of the two support frames set together
	and the conveyor belt table set in its "real"
	location.
	
	DrumSander006.jpg
	Exploded view of the table support mechanism.
	I bought a chunk of 1" acme threaded rod from
	www.mscdirect, and cut it into 16" lengths.  I
	turned down about an inch on one end and a bit over
	2" on the other end to 5/8" to fit the bearings
	and sprockets I had picked up.
	
	DrumSander007.jpg
	Close up of the sprocket end of the table
	support mechanism.
	
	DrumSander007a.jpg
	The table support mechanism set more or less in
	place on the machine frame.  Note that the nut
	will get welded to a bracket that will bolt to the
	conveyor belt table.
	
	Leveling adjustment is done by either shimming the
	bracket, or, loosening the set screws holding the
	sprocket in place and turning the screw slightly.
	
	DrumSander008.jpg
	Close up image of the pulley end of the drum support
	axle.  1" steel rod (also from MSC), turned to
	5/8" to fit the pulley bore.
	Note that this is sitting on top of the top support
	frame rail.  It will, though, be bolted to the 
	BOTTOM of the rail when all is said and done.