Flapwheels are pretty neat. Depending on the grit they can remove material fast, or finish a surface quickly. They can be used on irregular shapes, curves, holes and other places where conventional powersanding tools have a hard time getting to. They last a fair while, too.
Problem is, those things average at 5-10$ per piece, which is quite expensive even if they last a while.
So I figured, let's make a simple poor man's version which uses regular sandpaper. Sure, the given design doesn't remove as much material as quickly, nor does it last as long as a proper flapwheel, but it's a heck of a lot cheaper. For the price of one real flapwheel you can print one or two of these poor man's flapwheels AND get at least half a dozen sheets of sandpaper which you can use with this contraption. It'll take longer to use, but it's definitely cheaper.
So what I designed here is basically a clamp using two M3 nuts and two M3x10mm countersunk screws to clamp a folded piece of sandpaper and which you can chuck into a drill. Super simple to use and works quite well.
- Super cheap
- Can be used in forward and reverse, unlike traditional flapwheels which can only go in one direction
- Because it only has two fans and they're rather flexible, you can spin it up and 'dive' into a hole, not only sanding the inside but automatically chamfering the edge
- Less sandpaper fans, so it's slower than traditional flapwheels
- Changing the sandpaper takes a minute and needs a screwdriver
- Need to prepare replacement sandpaper pieces