Used up welding rod stubs should be just long enough to be usable. Break any flux coating with a hammer without bending the rod, and use a wire wheel to clean off any remaining flux or rust from the rod. The best material I found to use for 1/8" shank is a piece of 1/8" welding rod with the flux removed. Finally, carefully spin the remaining water out of the plug by allowing it to spin with the reaming bit fully inserted and increase speed slightly until all the water is slung out of the plug. Ream the shank hole with a diamond bit to enlarge the hole so the shank is an easy fit leaving a little room for glue. Pry the plug from the wheel and it will easily snap off.Ĭheck to see if the shank material will fit easily, the 3mm size is a tiny bit smaller than 1/8" (3.175mm). Stop cutting the plug just before breaking through the last half millimeter so the plug doesn't get stuck inside the hole saw.
Don't worry if the shank hole is a little off center, the bit will be trued up concentric later. Now without moving the wheel, remove the 3mm bit and insert the larger hole saw to cut the plug diameter concentric to the hole for the shank. Stop drilling perhaps 1/4" from going through. Drill the hole for the shank first with a 3mm diamond hole saw at low speed. Position the grinding wheel on the table so that a plug will be formed by the diamond hole saw will be just inside the outer edge and clamp it to the table with a spring clamp. Cover the drill press table with a plastic cutting board to help keep it dry. Make sure the axis of the drill press is perpendicular to the table before starting. Soak the wheel in water for a few minutes before drilling it, the water absorbed by the wheel is enough to keep the diamond hole saws cool while cutting. The grinder wheel is porous and will soak up water like a sponge. I haven't experimented much with finer grit wheels, but I would expect them to cut slower with a smoother finish - and more likely to burn. You can feel the face of the wheel and tell if the abrasive particles feel sharp or rounded - the sharper the better! The grit size should be a coarser grade, a smaller grit number designates a larger particle size the same way as sandpaper. I bought a white aluminum oxide 60-80 grit 8" x 1" from Harbor Freight for $9.99, and I lucked out because this wheel seems to be perfect for this project! I also tried a 24 grit gray aluminum oxide wheel that didn't work well at all.
Regular bench grinder wheels do not have this reinforcement.Ĭhoosing the right grinder wheel to make the plugs from is critical. Those types of wheels have fiberglass mesh embedded in the wheel for strength. Try carving a scrap piece of pine before and after the dressing process to see the difference it makes.Ĭaution - do not use this for making large diameter cut-off wheel type bits. You don't need to remove much material from the grindstone to sharpen it. The objective is to make the grinding wheel as rough as possible while also truing it to be perfectly concentric. You can also use a diamond blade for an angle grinder. Dress the grinding bit by spinning it at low speed against a diamond bit (preferably larger diameter and coarse) spinning at high speed in an electric drill in a way so that the rotation axes are crossed, and the scratches formed on the bit cut along the length of the grinding bit or at an angle. If you would like to try a bit like this before investing in new tools to make your own, you can use the tan or orange Dremel grinding bit that is typically a little smaller than the 1/2" rubber drum sander. If you like what you see, please subscribe to my YouTube channel. Watch my video showing how the bits are made and demonstrated first. They can also be in different shapes such as cylinder, ball-nose, dovetail, v-wheel, flame, or other shapes as needed. The results will blow away the temperamental Dremel sanding drums because they can be used at higher speed with perfect balance and concentricity - no more broken or worn out sanding bands! Oh yeah - they are also re-sharpenable, and can be made larger for tools such as die grinders.
#Dremel tool sanding bits how to
This Instructable will show you how to make your own sanders / carving bits from an inexpensive grinder wheel.
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