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Flush Trim Sander

for the Small Shop

Ken Picou Design
5508 Montview
Austin, TX 78756

Your new Robo-Sander™ is designed to allow you to duplicate parts quickly and accurately. It works in much the same way as a flush trim router bit, but poses little risk to you or your work and requires only a drill press to use. I routinely use it to shape all the curved parts on a side chair I make, including the backrests which are over 2" high.

All Robo-Sanders™come with a 50 grit sleeve and are ready to use. If you have purchased the 3" Robo-Guide™ Remove the lock nut and thread the unit snugly into the bottom nut of your sanding drum. Do not over tighten.

If you will be using the Robo-Sander ™ often, it will be worth your while to make a sub-table for your drill press. Use 3/4" material with a hole cut about 1/4" larger than the O.D. of your drum. This way you can adjust the Robo-Sander ™ to templates of any thickness and even lower the guide beneath the table to use the drum freehand . If you will only be using the Robo-Sander™ occasionally make your templates out of 3/4 material and forget the sub-table.

Mount the drum into into your drill press and lower the drum so that the bottom edge of the abrasive is just touching the top of the template. Lock the drill press in this position. I usually run my 3" Robo at about 1800 rpm. (maximum recommended speed is 2500 rpm.)

For best results bandsaw your stock a just bit oversize before attaching it to the template. Sand along the template with a steady, even, moderate pressure until the guide stops the drum from sanding. If there is any discoloration of the wood run the Robo-Sander ™ at a slower speed or use less pressure when sanding .

In a pinch, stock almost twice as tall as the Robo-Sander ™ can be shaped by first sanding the lower half of the stock flush to the template. Flip the stock and use the sanded surface as the template to finish off the stock. This method is tedious but it works .

A simple but effective dust collector can be made from a gutter downspout with end caps or a pvc slip-tee with a slot cur out. Attach a shop vac and your work environment will improve greatly

The template guides can be run either top or bottom on all Robo-Sanders™ .The 3" model requires two 1/2" spacer washers to clear the top flange.

A robo sanding station can be made by making a table similar to a router table and using a 1/3 to 1/2 HP 1725 rpm motor. Mount an extra long threaded work arbor (available at hardware stores ) to the motor. Devise a frame with an up / down mechanism which you can lock in position perpendicular to the table. With the guide mounting bolt removed the 3" Robo-Sander ™will thread directly on to the work arbor . Use a keyless drill chuck for the smaller Robo-Sanders ™. An effective dust collector can be made from short length of 3-4"dia. pvc pipe mounted to an overarm so that it sits directly above the drum.

Caution: Never use the Robo-Sander ™ in a router or shaper. Maximum safe operating speed is 2500 rpm. Wear eye protection. Do not touch the Robo-Sander ™ while it is in motion. Use common sense.

Trouble Shooting: If the guide wheel binds after changing sanding sleeves , disassemble and flip the washers . They can bend if overtightened.

If there seems to be a lot of runout after changing sanding sleeves, Loosen things up and rotate the sleeve a half turn in relation to the rubber drum.
*Note: Many hardware store sleeves are very light weight and tend to distort.
Better results will occur when heavy dutly sleeves are used.

I like feedback ...Please send me comments and photos of your work.

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