Woodworking - How to fix this (Plywood tube)

Martynt74

Martynt74

Martynt74

Soldato
Joined
20 Feb 2004
Posts
22,778
Location
Hondon de las Nieves, Spain
Hi Guys

Got a hole saw and cut about 14 circles out of birch ply. I tried to line them up as well as i could when glueing together. However on a few pieces the hole saw has destroyed the edges quite badly.

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My initial instinct was to sand the hell out of it. I mounted my orbital sander on it's side, but that ended up with a few flat spots, and in some parts seemed to make it worse.

Then glued some sandpaper to a block and tried rolling the hole unit along it to try and flatten it out but that didn't seem to do much.

I imagine what would be ideal would be a huge belt sander. I do have a regular belt sander but need to pick up some belts. The issue here would be the risk of taking off way too much.

I imagine you can all see the look i'm going for. I think it was @divuk83 who's made some great plywood based tables/benches using the same tactic (though better implemented).

I did see something called Wood Grain Filler but not sure that'd work.

Any tips on the best way to go about tidying this up?

I've got some clear varnish to
 
Cheers. I had thought a lathe but that’s one of the few things I don’t own!

The drill idea could be decent. As you say I’d just need to support the other end as it’s pretty long so would put a lot of strain on the motor.

The plan is to use a clear gloss varnish. I did use some pva/sawdust on a few bits where I had gaps. It’s mainly just to fix the rough bits. Think just lots of hand sanding is probably the way to go and accept it’ll take a lot of effort.
 
Will have a play tomorrow. Cheers

What’s annoying is I’d mounted them all one a bit of dowel which in theory should’ve kept them all in line and had just cut the spare ends off. They would’ve been perfect for mounting in a drill!
 
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