Make Your Own Random Orbit Sander Disks?

[Darryl Young]

I have an old 5" Porter Cable ROS that uses the 5 hole pattern PSA disks that aren't that popular now. I wanted to order sanding disks appropriate for finishing but each grit comes in 100 disk rolls and are roughly $27 per roll plus shipping. So I don't want to order a particular grit unless I really need it. Also, I'm uncertain if I want to invest this much money in sandpaper that matches the hole pattern for an old random orbit sander (what if I need to buy a new one soon and it has a different hole pattern?).

I happen to have the same paper, Carborundum Premier Red Dry Lube, in P400, P600, P800, P1000, P1200, and P1500 grits. Any reason I couldn't use an old disk as a template and cut disks, including the 5 hole pattern, from the sheet paper stock? I could then spray the back of the disk with 3M Super 77 spray adhesive right before attaching to the ROS so they stick like a PSA disk.

Maybe then I'll figure out which grits I need to order so I don't have rolls sitting around unused. Think it would work? I've heard you can buy a punch to cut the hole pattern that matches your ROS but I've never seen one. If true, I could buy paper without holes and if I change ROS, I would just get a different punch for the new sander and could still use my existing sanding disks.

[tippie53]

yes you can
If you have a drill press and vise you can make a simple punch.
Drill a hole of the same size , You can make it a bit larger or smaller. If you have say a 3/8 drill take an old 3/8 bit and grind the chuck side flat and then chuck it upside down then use the press as a punch

[Darryl Young]

That's not a bad idea.

For the record, I tried this the other night and it worked. Used P400 and used P800 disks cut from 9X11 sheet and sprayed with Super 77 3M glue.

[Kevin Sjostrand]

Way to go Darryl. I've made discs for my combo 6" disc/belt sander this way for years.....

Kevin