I guess I never thought about that but it makes sense. The Klingspor discs have more holes then I need but work great although I have never done a side by side comparison to discs with the proper number of holes
I bought the one from Oneida and it works great in fact I just emptied the bag a week or two ago, the first time in 2 years LOL. They are pretty proud of it though @$300 so a home grown solution may be the way to go.
I know pretty crazy considering I told my wife 6-9 months
Having said that I am very happy that I came in under less than a $1000 over budget which which was $17K below the lowest bid and the bids did not include any theater chairs or AV equipment which was nearly $19K. On top of that it's been done the way I want with few compromises and I was able to change things on the fly as desired. I'd be lying if I said I wasn't ready to be done but we are very happy with the results and I'm more then proud to put my name on the work I have done
As always the bonus was learning new skills along the way:
Understanding sound proofing and room isolation
Constructing and drywalling curved surfaces
Pouring epoxy countertops
Working with LED lighting
Painting doors and trim with an HVLP system
Now I am sooo close to getting back to making furniture I was even thinking about making a run to a new lumber yard in sothern MN to see if I can get some lumber for the spectator chairs and a couple of small bar stools one behind the bar and one by the drink shelf for when we are playing darts. This thread should be a wrap fairly soon heading out to put the top coat on the vanity now...
The problem is that nails alone are not a terribly strong joint for the firce that piece endures. However, you should be able to restore it to its former condition. Carefully work the nails out and stratighten them. Use a dab of wood glue and toothpick or bamboo skewers to fill the holes (only in the frame, not the cross bars). After the glue has set, clamp the cross bars into position and drive the nails back in.
I would leave one hole at each end only half filled, so the nail can be pushed in to help align the others. That, and binding the bars together with twine should hold the in place firmly enogh to drive the remaining nails without displacing the parts. If you have means to clamp the frame to a workbench or other solid structure, so much the better.
If you want to pursue a more structurally sound solution, there are options, but they require more skill than driving a nail.