Sometimes, the tool you need the most doesn’t exist. It’s at that moment that you realize…Hey, I could make one of those! I’m doing an awful lot of edge cold working and don’t have a lap wheel, and my hand held polisher isn’t fabulous for edges. So, with a little ingenuity and a sharp hack saw, a new bench polisher is born.
I started with this tile saw, since I can’t use it as a saw. (don’t buy one, it’s horrible piece of equipment)
Then I started to disassemble it so I could rebuild it into something that was actually useful.
Once I got the blade guard and other stuff out, I found this handy adapter at the hardware store. This will re-thread the shaft of the saw motor to accommodate the 3″ diamond polishing pads from my hand held polisher.
Luckily there is an adapter that fit this saw. I have another old tile saw that has an extremely odd size of thread with no known adapter.
Now the hacking part. I started by sawing through the black plastic rim of the saw on the reservoir side of the saw. I set that aside, as I’ll need it later.
Next I needed to reduce the height of the plastic walls so I can get my glass to the polishing wheel.
The plastic walls that are left are really flimsy, so I added some reinforcement in the shape of maple sticks.
And then put the black rim back on by screwing it down to the maple reinforcements.
Next, I added two maple crossbars that act as a work surface. I will probably find a more elegant solution at some point, but these are easy to make and removable for a more versatile set up.
It looks to me like this thing is going to make a heck of a mess when I add the water feed and use it, so I hacked up a plastic bin to make a splash guard and added a gallon of water with a thin piece of surgical tubing. I could have installed something more permanent in terms of a water reservoir, but I use this jug and tube set up for drill and carving, so it seemed easiest to have a multi-use solution.
I’ve pulled it forward so the drain hole in the reservoir is directly above a bucket. At some point it would be good to add a tube to the drain, but for now, I’m in business!!
Disclaimer: This article is for entertainment purposes only, it is not meant as a guide or tutorial. Hacking power tools can be dangerous and should be done at your own discretion and with great caution (if at all). Be smart people, safety first!