To make any variety of exactly sized disks, I constructed a micro-adjustable jig for my disk sander. A small runner matches into the sander’s miter slot to maintain the bottom of the jig secure, whereas permitting it to be moved aspect to aspect to entry recent areas of the sanding disk. Up high there may be one other slot, perpendicular to the disk, which holds a skinny sliding bar with a 4d (4 penny) nail protruding close to the tip. Hanging off the sliding bar is a threaded rod that hits the entrance of the sander desk to restrict the depth of lower. After roughing a workpiece to measurement on the bandsaw, drilling a 3/32-in. gap at its middle, and tapping it down onto the nail, you simply slide the workpiece ahead as you rotate and sand it. When the threaded rod touches the desk, the disk is at its last diameter. Changes are easy, and also you get easy, exact disks each time.
—CHIP TREBOUR, Richmond, Va.
Illustrations by Dan Thornton
From High-quality Woodworking difficulty #288