I started using the little disc I made previously with the holes in them and I went through about 20 of them in a hurry. So I thought there has to be a better way, and you won't believe how good this works. You don't have to drill the holes and cut the discs to size to start with, just put them on the holder and cut the edges as they wear down. The plastic backing on the disc itself helps keep it rigid and I cut right through the plastic as I get them smaller. There is nothing cumbersome about this holder.
What you see here is a 7/16" i.d. coarse threaded nut and 1/4" bolt about 1-1/2" long. After you get the nut, twist it on the roloc disc. The first one I picked up, one side of the nut would tighten up fairly decent and the other side of the nut slipped a lot, in other words it wouldn't tighten up much. It will start a little crooked on the disc and as you tighten it up, it will flatten right up against the disc. If you twist it too much, it will loosen and tighten up again, but it will hold when you go to grind with it. Trust me, this thing will work.
I just stuck the end of the bolt on to the end of the nut in the vise, snug it up a little bit then eye-ball it. You can tap it with a hammer to get it so it looks straight, close enough...doesn't have to be perfect. Now weld the bolt to the nut.
Here is the complete disc holder. I took it over on the bench grinder and rounded the weld off a little bit.
This is a comparison of the size of a disc that is worn down to the original roloc holder and you can see how much smaller this one is.
Another picture of a disc that has worn down as far as it can be on the original roloc holder.
[ 1 ] [ 2 ]