Cheap and easy sandpaper pads
I love the effect of power sanding but am too cheap to buy precut sanding pads. Previously I had bought large hook and loop pads and cut them to fit my foam sanding attachment. It took a lot of time and the final size was not as consistent as I would have liked. Today I finally did something about it. I had a bunch of 7″ hook and loop pads so it was the perfect reason to upgrade my method.
I started off by selecting a hole saw that matched the size of my sanding pad (about 2.25″). I swapped out the drill bit and mounted it on the lathe. At slow speed I used a grinder and removed most of the teeth and made a sharp edge. I mounted the modified hole saw in my drill press and tried it out. With the sharp edge and slight teeth it worked great. I was able to get 8 disks out of a single 7″ sanding pad, all perfectly cut! The hole saw holds the disks so you can cut a bunch without stopping. I was even able to cut through 2 layers at once with no problem. I made 16 sanding pads in under 30 seconds.