Tuesday, January 31, 2017

How to Fix a Delta Belt Sander With a Burnt Out Motor

Difficulty Level (Easy, Medium, Hard, Insane):

I bought a 4x36 Delta belt sander off kijiji for $25 and once I got it all cleaned up and plugged it in, it took less than 30 seconds for the motor to go up in smoke.

At first I thought it was just some sawdust burning but the motor was completely fried. After some research in rewinding motors I decided not to pursue that avenue but instead see if I could take one of my 1/2hp motors I had lying around and adapt it to my belt sander.

After turning down the motor's flange on the lathe, I cut a hole into the case of the belt sander, drilled some holes for mounting bolts and mounted the water pump motor into the housing of the belt sander.

The next thing I had to do was to hook up the wiring, drill a cross hole to the belt gear and set it with a 1/8" roll pin.

After that I built a pedestal around the base of the belt sander because the water pump motor was larger than the base.

The last thing I had to do was to cast and turn a disc for the 6" side sander. That part turned out to be a bit tricky. I ended up having to do it two times because for the first one I drilled a hole that was too large, then I wanted to fix it by pressing a matching plug into the bored hole with my 20-ton DIY Shop Press and re-drill it at a smaller size but I cracked the flange because I didn't support the part properly (I just learned the first lesson when it comes to shop press useage)

After I finished the disc and installed it on the belt sander, all that was left was to install the sand paper on the disc and I was done.

Close-up of the model

Motor specs

The burned out motor

The belt sander after I took out the dead motor

All the parts that came off

The burnt wiring

Close-up of the burnt wiring

Pressing the rotor out of the motor housing

The order for the drive belt

The original drive belt

Getting ready to install the motor in the cut-out sander base

Fitting the motor into the sander base

Turning the face plate of the motor flat

Another view

Fitting the motor into the sander base

Another view

The installed motor with the wood base

Another view

Getting ready to wire up the motor

Another view

The finished belt sander sans side disc

Another view

Turning the side disc

My son helping me out

Using a 10mm end mill to drill the hole

Accidentally drilled the hole too big 

All I had was some square stock
Turning down a plug to press fit into the hole that was too big
The finished plug

Turning it down to size

Chamfering the plug

After I cracked the disc hub during press-fitting the plug into the undersized hole

Drilling a hole through the motor shaft and pulley, then installing a 1/8" roll pin

Cutting off the excess of the motor shaft

Installing the drive belt guard

The back side of the belt sander

Starting to drill the hole on the second version of the side disc

Another view

The finished side disc

The back side of the finished side disc

Test-fitting the side disc

Tapping the hub for a set screw

I had to grind a slot into the end of the tap so I could use a screwdriver to tap the hub

Tapping the hub with a screwdriver

Test fitting the side disc with a 5" PSA sanding disc

Another view

The back side of the sander

Aluminum foundry & accessories
Propane burner
Metal lathe & accessories
Metal band saw
Cordless drill
Screw drivers
Ratchet & socket set
Table saw
Chop saw
Angle grinder
Eye & ear protection
Air compressor
Air nailer

1/2 hp water pump motor
3ft of 2x4 lumber
Nails & screws
Wood glue
2 lbs aluminum
One drive belt


5 hrs


It works great. I've already used it several times


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