Restoring and Upgrading a Tired Old Sander With 300% More Power | Part 1 of 2

Most DIY people get annoyed with their non-professional grade tools at some point or another, but don’t want to spend thousands of dollars to reach professional or contractor grade performance. Maybe restoring and upgrading your old equipment is the best option?

It’s me! I am most people!

But let’s be real, it’s probably you too…

That is exactly what has happened here. When I was looking for 3hp, 220v, single phase, 6×9 metal working sanders that had the specs I wanted, I was finding them to be well over $3k+, so I decided to upgrade what I had for 1/10th of that.

Here is a good example of what I aimed to build:

So,

In this article, I will be walking through the disassembly and teardown of my 6×9 (6×48 belt) belt and disc sander restoration project. This is easily doable by most capable do it yourself mechanics, and I would be inclined to think if you are the type of person to read an article like this, you are more than likely capable of doing this rather easily.

This is also shown in more detail in a video here:

Why Upgrade Your 6×9 Sander?

Before we dive into the steps, let’s discuss why upgrading and rebuilding your sander is essential:

Improved Performance:

Over time, dust and debris can accumulate inside your wood working sander, affecting its performance. A thorough cleaning and rebuild can restore it to its optimal condition. In this case, we are upgrading the sander by 300% power and we will need to upgrade certain components such as bearings, wiring, and mounting for more rigidity and usefulness with metal.

Longevity:

Regular maintenance, including disassembly and cleaning, can significantly extend the life of your sander. While we have it apart, we are replacing/upgrading the moving pieces, restoring the metal barrels, and repainting the surfaces to protect against corrosion with a resistant paint that will hold up better against metal debris and chemicals.

Cost Savings:

Rebuilding your sander is often more cost-effective than purchasing a new one. Especially in this case, as the performance I am aiming for is readily available, but at a purchase price over 10 times what I have spent here. It is however, important to use high quality components to achieve a high quality outcome.

Disassembly and Teardown

Tools and Materials Needed

Most of these tools are a part of the basic workshop tool set an enthusiast tinkerer should expect to need, to see what that list looks like, see our Beginners Guide on setting up a home workshop, to include basic tools.

To disassemble your 6×9 sander, you’ll likely need the following tools and materials:

• Various Screwdrivers (Phillips, flathead, and allen-Ts)
• 3/8 Ratchet and various sockets
• Pulley Puller
• Various spanner wrenches (the ratcheting kind are recommended for faster use)
• Allen wrenches for tighter spaces
• Regular pliers, and snap ring pliers
• A clean, organized workspace
• Replacement parts (bearings, snap rings, pins, hardware, sander disc and belt, etc)
• Cleaning supplies (compressed air, soap & water, rags, etc)
• WD-40 or PB Blaster
• Resilient paint

Step-by-Step Disassembly Guide

1. Safety First

Ensure the sander is unplugged. Wear safety goggles and gloves to protect yourself from dust and debris.

2. Remove the Sanding Pad Disc

Start by removing the sanding pad. Depending on your sander model, this may require unscrewing or simply pulling it off. You can use WD-40 to help loosen the adhesive once you get behind it. Carefully pry this off once the set screw (if there is one) has been removed. I unfortunately broke mine as it was seized on the pulley shaft key.

3. Remove the Belt and Pulleys

Once the Disc face plate is removed, you can access the pulleys. You will want to remove tension to release the belt first. Then remove the set screws. Once the Set screws are removed, use a pulley puller to remove the pulleys from the shafts, a penetrant or lubricant on the shaft key way will ease removal.

4. Remove the Sander Housing

Once the pulleys have been removed, use the appropriate tools to remove the screws or bolts holding the disc sander’s housing together. Carefully set the hardware aside in a container to avoid losing them.

5. Remove the Upper Belt Sander Assembly

Once the housing has been removed, observe how the main barrel in the belt sander assembly is secured. Look for any obvious signs of wear or damage as well, and take a photo to remind yourself of any orientations. You will want to support the assembly as you remove the hardware holding it on. Be careful not to let it sag as the main frame is a cast material that can crack or break if there is too much weight at an excessive angle.

6. Remove the Motor

Carefully disconnect the motor from the cast sander base. This will involve unbolting it from its mount and disconnecting any wiring harnesses. Take pictures of any wiring (you can see me doing this in the video as well, even though I did not end up reusing this wiring). Carefully set the motor aside as it can often be reused in future projects.

7. Disassemble the Upper Belt Assembly

If necessary, disassemble the individual components for a thorough cleaning. Use compressed air and/or a vacuum to blow out dust and debris from the assembly. Unscrew or remove any tensioning components for the belts, take pictures or record the orientation or order of the pieces. To remove the barrels, you will need to undo the tensioners all the way so that the swing arms can come out with the barrel.

8. Disassemble the Base:

Once all of the components have been removed from the case base. Remove the hardware for the upright mount and any other separable pieces in preparation for cleaning.

9. Clean All Parts

Use brushes, rags, and compressed air to clean all parts of the sander. Pay special attention to the bearings, gears, and any moving parts.

10. Inspect and Replace Worn Parts

Check for any worn or damaged parts that need replacement. Common parts that may need replacing include bearings, brushes, and belts. In our case, we are rebuilding and restoring the whole unit, so everything gets replaced. Record any measurements and part numbers that are visible.

Tips for a Successful Teardown

Take Photos: As you disassemble the sander, take photos at each step. This will help you remember how everything goes back together. Even if you don’t end up using them.

Organize Screws and Small Parts: Use containers or magnetic trays to keep screws and small parts organized. I like to use the small plastic tubs for things like this.

Keep everything clean: It is important that you do not overlook a retention ring because it is covered in grease, or drop debris into a difficult to remove and sensitive space during disassembly.

In Closing

Disassembling and rebuilding your 6×9 sander is a worthwhile task that can enhance its performance and, in our case, restoring and upgrading it for metal work and withstanding a much more rigorous working life. By following this guide, you can ensure a thorough and successful rebuild. Regular maintenance not only saves you money but upgrading can also keep money in your pocket as opposed to simply replacing an old, worn out machine.

To continue on the journey, move on to Part 2 for the completion of the 6×9 sander restoration project here.

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If you have any questions feel free to leave a comment or contact us directly.

Happy Building!