I have a 25mm broomstick and I need to reduce the diameter to 22mm on about 100mm from each end. The center part should remain at 25mm. I'm trying to figure out how to do this using basic tools like chisels, a drill, circular saw, mitre saw, hand router, and palm sander. Unfortunately, I don't have access to a lathe or router table to make it easier. Sanding has proven slow and imprecise, and I've seen Dowel Jigs and Plates that max out at 20mm. Is there a technique or tool that can help me reduce the diameter without too much hassle?
3 Answers
I've tackled a similar project using a tablesaw. Position the fence so that it's 12mm from the blade (half the dowel's diameter). To remove 3mm, set the blade height to 1.5mm. Spin the dowel steadily while feeding it into the blade, resting the side against the fence. You can use a cordless drill to spin the dowel by inserting a hex screw in the other end. Just make sure to go slow and check your progress!
When you say you're sanding, are you hand sanding? I've had success using a drill to sand down my dowels. I just wrap sandpaper around them while they spin in the drill. It gets hot, so wear gloves, and use a low torque setting if you can. I stop every now and then to check against a template for a tight fit, and it usually takes me 2-3 minutes per dowel. Just be careful of the end connected to the drill; you might want to cut it longer to trim it afterward!
Thanks for the tip! I'll definitely give that a try.
Have you thought about rigging up a basic lathe? Check out this video for a makeshift setup that could work for you! [YouTube Link](https://www.youtube.com/watch?v=gUT8doDpBI0) You might find it really helpful for your project!
That sounds like a solid method! Just be cautious with the heat, you don't want to burn the wood.