Worx Chopper Sanding Wheels

Here are sanding disks for a Worx Chopper. There are 2" and 3" sizes, and a flat and convex version in both sizes.

The procedures described in this Instructable apply to all versions of the sanding disks. I might design a printable Dust shroud specifically for these sanding discs. If I do, I will post a link here. Please note, you have to remove the manufacturer's dust guard of your Worx Chopper in order to use these sanding disks. The pictures of a wood block are before and after sanding pictures using the 3" Flat version. 120 grit sandpaper was used on an oak block and it exceeded my expectations. Because the grinder doesn't have a side handle, it takes a steady hand to get good results, but the tool is more than capable. I might design a side handle, and if I do I will also post a link here.

Materials:

-Velcro hook pad ( https://a.co/d/9wMp4v3 will work!)

-2" or 3" Sanding Disks (3": https://a.co/d/98lNYY4 2": https://a.co/d/9ob8vyR (these are for wood))

Printed wheel: https://www.printables.com/model/613565-worx-chopper-sanding-wheels (print instructions are at link)

Tools:

-Worx Chopper 3" cutoff tool ( https://www.worx.com/20v-3-inch-mini-cutter.html )

-Xacto knife (hobby knife)

-Wet wipe (optional)

First, make sure that the large face of the disk is clean. This will help the Velcro stick on to the disk better.

If you use Velcro other than the link in the materials list, make sure that you have enough to overlap on the edges of the disk. The seam in the middle of the disk should be a flush butt joint. I do not recommend using more than 3 pieces of Velcro.

Stick the Velcro onto the disk with the seam down the general middle. Smooth the Velcro out once stuck onto the disk for a better grip. Then, using an Xacto knife, trim as close as you can to the edge of the disk. After the main edge of the disk is trimmed, find where the Velcro is squishy in the center of the disk. Pierce the Velcro in that spot with your Xacto knife and cut one direction away from the middle until you hit an edge. Then follow that edge all the way around. Having done that, you may want to brush up the outer edge of the disk with sandpaper to remove the fringes of the Velcro. If necessary, you may also want to make sure that the bolt to mount the disk fits properly. If not, trim accordingly.

In my experience with Velcro sanding disks, no matter how hard you try to center the sandpaper on the disk, it will always move as soon as you turn the grinder on. This isn't that big of a deal, and the only negative effects are edge wear on the Velcro and sandpaper. It would be interesting to try rubber backed Velcro for a softer sanding disc. Let me know if any of you makers try it! Thank you for reading this Instructable. If you have any questions, comments, concerns, or future project ideas, let me know! I will be happy to hear from you. Thanks!