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Free Metalworking Project Plans: 2″ x 42″ Belt Sander


Material: Steel and Aluminum
Units: (in)

Here’s another nice set of plans for the Miscellaneous category, submitted by Bill P. Here’s what Bill had to say about his 2″ x 42″ Belt Sander:

“A little background: 2-3 years ago I got them off the HSM forum from member George B. The sander is a good resemblance of an existing commercially available sander – I have seen pics of a couple but don’t know what brand. At a later time I asked George – through the HSM forum – if he minded my giving copies to a couple friends and he readily agreed, so Ive been parceling them out here & there ever since.

As typical of us HSM’ers my friend and I tinkered around with the plans — as drawn, they are for a 2×42 size, but 2×42 belts can be a bit of a problem to locate, and get a selection of grits, whereas 2×48 are readily available and in a wide assortment of grits, so — we just added 3″ to the height of the frame! Also the plans don’t show a table & platen or any type of belt guard so we got that on our versions also.

There can be a bit of a snag to making the sander in being able to find the 2 wheels – especially the 6″. Since I had done all of Dave Gingery’s projects and had a furnace, I just made a mold and cast the wheels. Have heard of guys using casters, and supposedly, laminated wood!. And apparently, there are some commercially available wheels the knife makers use in making their big belt sanders — that’s where the scrounger in you can shine!

And speaking of “scrounging” — the first one I made was in the 2×42 size (how I discovered the scarcity of that size belt!) and I used what ever was laying around the shop. I had a 1hp 1750rpm motor and a piece of 1/4″ plate steel, so I made it up using that. The motor was non-reversible so I had to devise a jack-shaft. I later got a 1hp 3350rpm (you really need the 3350rpm!) motor and a nice piece of aluminum so I made the next one in the 2×48 size and added the table, platen and guard.”

– Bill P.


Thanks for submitting the plans Bill!

Please feel free to link to them on the HSM forums to direct others here for download. I know many forums don’t let you post documents for download due to bandwidth concerns, so you can write the project up in the forum, and send people here if they want to get a copy of the plans. After all, that’s what this site is here for – to share great plans and make them available for free downloading by anyone interested.

Update (12/18/2009): Fransisco sent me pictures of his completed sander a few weeks ago. Here’s what he had to say:

Hi Tyler!!
I want to tank you for share this plans. I built it and can say this sander is very useful tool. I’d love it!!. I Live in Brazil and the belt used was 1″ x 48″.
Well, tanks again!!



Thanks for sharing Francisco. Your sander looks great!

If anyone else has a nice set of plans to share or pictures of a recently completed project, please send them via the “Submit Your Plans!” tab at the top of the page.

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About Tyler

Tyler is a hobby machinist and 3D printing aficionado. He teaches computer programming and web development at Highline College near Seattle. Tyler founded Projects In Metal in 2008 because he was frustrated by the lack of free plans available for hobby machinists.

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  1. Hello
    Thank so much for your time.Am Mark and i will like to order Free Metalworking Project Plans: 2″ x 42″ Belt Sander , Material: Steel and Aluminu and what is the price for this and also what type of payment do you accept..Thank you and waiting for your reply.


  2. Hi Mark, you can download the plans for free by clicking on the PDF file above. Let me know if you have any trouble downloading/opening the file. Thanks for your interest!

  3. This sort of sander is one of the most useful tools in my shop; I think it was once called a “linishing machine”. For those not wanting or able to make one, Veil tools in Canada make the “Viel S5 Sander-Grinder” and without motor is only $85 Cdn. The belts are 1″ x 42″ and a wide assortment is available from 42 to 1200 grit. FYI only.

  4. Francisco Tesifom Munhoz

    Hi Tyler!!
    I want to tank you for share this plans. I built it and can say this sander is very useful tool. I’d love it!!. I Live in Brazil and the belt used was 1″ x 48″.
    Well, tanks again!!

  5. Excellent Francisco, I’m glad you liked the project! Send me a picture (or pictures) of your sander and I’ll put it up on the site.

  6. Thanks for the info Jim!

  7. Hi Francisco, I finally had a chance to upload the pictures you sent me of your finished sander. Thanks again for sharing and happy holidays!

  8. thanks man , i live in Bolivia , and your project save my day .
    best regards

  9. very greatful for these plans i am a teatcher in cnc-machining and was all dryed out for ideas about what to do with mine students,this seem`s like a great forum to share ideas and i will tribute with some of mine own plan`s as son as find the time for it.bets regards Stefan.(Sorry about the spelling i`m Swedish.)

  10. Hi Stephan, I remember getting this comment a few weeks ago in my e-mail and I thought I had replied. I guess I didn’t. Anyway, I’m glad that you like the plans. If you’re willing to share some of the plans that you use with your students I would be very grateful. I have a few sets of plans on the site that were generously donated by Bates Technical College in Tacoma WA. I’d be happy to include a link back to your school with any plans of yours that I post.

  11. Nice job guys hopefully I will have mine done soon and can join you


  12. Hello,
    With pictures, very well documented.

    thank you


  13. I am about to build one will post pics when done Thanks Tyler.

  14. Just finished mine Thanks Tyler for the plans. SmileFullSizeRender1.jpgImage Enlarger

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