Bill of Materials
 
Baseplate (1X)
1" by 6" by 6" Aluminum 6061 T6
 
T-Bar (1X)
3/4" by 1 1/2" by 4" Aluminum 6061 T6
 
End Plate (2X)
1/4" by 1 5/8" by 2 1/2" Aluminum 6061 T6
 
Set Screws (4X)
4-40 by 1/4"
Allen Socket Set Screws 
Alloy Steel
 
Button Head Socket Cap Screws (4X)
10-24 by 5/8" Alloy Steel
 
Guide Rod (2X)
3/16" diameter by 6 1/2" Tool Steel (60 Case)
 
Bearings (3X)
3/16" ID by 3/8" OD by 5/8" 
(Thomson Ball Bushings)
 
Bumpers (2X)
3/16" ID by 1/2" OD by 1/16"
Rubber
 
Wear Strips (2X)
1/64" by 2 3/4" by 6"
Plastic
 
Bottom Pad (1X)
6" by 6" 
Self-Stick Green Felt
 
The baseplate was made by cutting a piece slightly bigger than the 6" by 6" finished size to allow for machining. Then, the four edges were milled in a Sherline milling machine, using an end mill. A central slot of .500" by .135" deep was milled for the Miter.  The next step was to put the four holes in the baseplate that are drilled and tapped for the 10-24 by 5/8" Button Head Socket Cap Screws that secure the End Plates to each side of the Baseplate. (See the drawing for the locations.)
 
The T-Bar was then machined to shape and size, also on the Sherline milling machine.
The holes for the Bearings ( Ball Bushings) were then bored to size and locations.
 
Next came the End Plates. They were clamped together so they would be paired, and easier to machine. The adjusting slots were milled in after they were separated due to the ratio of the slot size to the thickness of the End Plates. ( Too easy for the slot to wander otherwise)
 
Guide Rods were cut to length.
 
So, we now have the Baseplate, T-Bar, End Plates, Guide Rods, Screws, Bearings, Bumpers, Wear Strips,  Bottom Pad ready for assembly.
All were made according to the drawings (which will be supplied) and/or purchased (in the case of the commercial items).
 
Assembly.
1. Take  the Bearings (3) and push them  into the T-Bar (1). (one at each end, and  one in the "tongue'"  of the T-Bar).
2. Using some self stick sandpaper of your choice as to grit to do the job, cut and affix a 1" by 3" strip to  the face of the T-Bar. (This is readily changed when required.) To fully utilize the sandpaper, simply flip the  T-Bar 180 degrees to use  the opposite edge.
Just unscrew an End Plate from one side and slide the T- Bar off to invert it.
3. Using double sided tape, secure the Wear Strips to the top surface of the Baseplate.
4. Fasten the Bottom Pad to the bottom of the Baseplate (This prevents slippage while in use)
5. Slip the Guide Rods into the T-Bar Bearings.
6. Slip  a Bumper on each end of the forward Guide Rod. 
7. The End Plates are then pushed onto the Guide Rods in the holes provided.
8. Using  the Button Head Screws, fasten the end plates to each side of the Baseplate.
9. Insert the set screws into the end plates, and tighten the 4-40 setscrews to the guide rods.
10. Adjust the End  Plates so the front surface of the T-bar with  the sandpaper strip is parallel to the face of  the front surface of the Baseplate without touching it.
11. A good way to do this is to put a piece of paper between the T-Bar and the Baseplate because paper is .003" thick.
12. Now fasten the end plates securely to the Baseplate using a 1/8" Allen wrench.
13. The miter was purchased from Jim Byrnes "Model Machines" of Florida.
That is about it. The Universal Sander is ready to go....
Jerry G (Glickstein)