Join Date: Nov 2016
Location: Winston Salem, NC
I have tacked flapper wheels to rods before and used them on the lathe. They work really well at smoothing out the high spots. Once things get smoother, they get less effective. Since you will probably be doing this be hand, you will probably want a half inch drill with a T-handle. A flapper wheel making enough contact to do any real work is going to generate quite a bit of torque.
Ball hones are available directly from Brush Research in many grit values and materials that are not available from a reseller. Some are stock items, some have to be put together and take a few weeks to deliver. If memory serves you can get them all the way down to 20 grit in some of the materials. I recently purchased a 1.75 ball hone in 80 grit Boron Carbide (BC) and they had that hone in stock ready to ship.
As stated before, home-made sandpaper flappers can be made using a wood form. They will require more attention because with fewer flaps they will wear quickly and you'll have to change the paper more often. I had a machinist friend that made a sanding head out of aluminum bar using a mill and an indexer, I think it held 5 pieces of paper. By nature these home-made tools are bore specific, but you can make them much longer than a flapper wheel or hone. 2 inches is kind of a small bore, so you might only be able to get 2 or 3 pieces of paper around a tool made to fit. Again, tools like this when held stationary in the tail stock or in the boring bar holder of a lathe are much easier to work with than if they are placed in a drill. For one thing you don't have to worry about balance.
I like to build things, even if they don't work.