Making a Magnetic Tumbler Page 3: Assembly Ideas

As previously stated, this is not intended to be exact, step-by-step plans on how to build a magnetic tumbler, rather it is intended to demonstrate how I assembled my units.  If you undertake this project, any and all risks associated with using any of the tools required will be your responsibility. Furthermore, you will be working with electricity and must have a qualified licensed electrician perform the wiring of the magnetic tumbler, and you may need a final inspection by a government agency before use.  BE CAREFUL!

 

 

 Cabinet assembly

1. Make a 12" x 12" x 16" high open-top box from 5/8" or thicker particleboard or plywood.  Use screws and  glue to assure a rigid and strong assembly.

2. Cut an opening in the back of the box for the vent grille.  Size will be determined by the exact size of grille you purchased.

3. Drill a hole for the powercord in the back of the box below the vent hole.

4.  Use a large hole saw or jug-saw to cut a circular hole in the front of the box the same size as the vent fan.  Round the edges with a router or file.

5. Cut a hole below the vent-fan hole for the switch plate

6.  Paint the box a waterproof color of your choice.  I used automotive "trunk" paint because it has a bit of texture.

 

Switch Plate Assembly

1. Cut a metal or plastic sheet into a convenient size to hold the switch.

2. Drill the appropriate size holes for the switch, fuse holder and mounting screws.   

3. Attach switch, fuse holder and power lamp (if desired) to the switch plate

4. Attach the plate to the cabinet with wood screws.

 

Fan Assembly

1. Measure the mounting holes on the fan

2. Drill holes in the cabinet that match the measurements taken from the fan

3. Mount the fan and fan guard with the machine screws.

 

Disc Assembly

1. Cut or purchase an 8" diameter circle from 1/2" thick particle board or plywood.

2. Lay out 4 equally spaced holes on a 6" diameter and drill these holes to the same size as the magnet diameter.  Exercise extreme precision in this operation to assure proper balance of the disc when the magnets are installed.

3. Drill 4 small equally spaced holes through the wooden disc and through the aluminum sanding disc.

4. Using small BRASS machine screws and epoxy, attach the wooden disc to the aluminum sanding disc using the holes drilled in step 3.

5. The bushing that is supplied with the aluminum sanding disc is unsuitable for a well balanced rotating assembly.  Instead, use a bronze bushing of appropriate size.  Place the bronze bushing into the 1.0" shaft hole in the center of the aluminum sanding disc head and mark the location of the setscrew. 

6. Remove the bronze bushing and drill a hole through it at the setscrew location and re-insert into the bore of the aluminum sanding head.

7. Slide the disc assembly onto the motor shaft and, using a longer screw the same thread and pitch as the original set screw, secure the disc to the shaft.

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