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  #1  
Old 04-28-2005, 08:56 PM
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chrisinbeav chrisinbeav is offline
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Home made 2x72 Belt grinder...

As of today my home made belt grinder is nearly completed, about 98%.

1 hp A/C Motor Ebay---$75.00 including shipping
8 inch contact wheel from Bulldog Caster---$35.00
1 piece of 2 inch angle iron---$10.00
5 aluminum casters Ebay---$16.00
Misc hardware (bearing, bolts, pullies, etc...)---$30.00
Total= $166.00



So here's how I did it....

Since I didn't even have a 2x72 belt when I started to make it I just used a piece of string that I melted together so I can keep the right size.

I started at the bottom...


I figured out where I wanted the main grinder wheel and notched out the bench top to give plenty of clearance around the wheel. My wheel/caster came preloaded with high speed bearings. So I mounted the wheel on a 1/2 inch axle bolt to a section of 2 inch angle iron. Then mounted the wheel and arm assembly to the bench top. I used a square on the bench top to make sure the the wheel would be at a perfect right angle to the bench top.

Next I measured how high I wanted the drive wheel to be and drilled a hole through a piece of 2x6.



Next I built the drive wheel assembly...



Here's the assembly left to right. A 5/8 dia 7 inch long bolt, drive pully(keyed), colar(keyed), bearing, 2x6, bearing, 2 aluminum casters, lock nut. The tricky part was figuring out how to keep the caster together. I ended up drilling and taping holes so I could bolt them together. (Major pain)

Looking at the same image of the contact wheel
you can see a black metal bracket that holds the 2x6 to the bench top. There's one on each side. I drilled out the 2x6 and mounted the brackets loosly.

Next was the really hard part... the pitch adjustable head...


The one pictured failed due to too small of a bolt. I'm going to use the same size bolt as in the drive wheel assembly. The wheels are basically the same minus the pully, so It's just nutted on that side. The wheel block assembly is mounted on a GM truck door hinge that I happened to have from my autobody days. Inbetween the 2 halves is a compression spring. The hinge assembly is mounted to the top of the 2x6 with some lag bolts. There are 2 rubber bushings from a radiator that allow the hinge assembly to be somewhat moveable. Using a cotter pin and a turnbuckle I made the tensioner. This is was controls the pitch of the head to adjust the belt for tracking. It's kind of crude.... but it seems to work alright.

Last was the easy part, setting up the motor and "V" belt.


The motor is mounted to the bench top using locking cams. That way I can slide the motor forward and back to adjust the "V" belt tension and if I change the pully size.

I still need to build the platten which will be real easy. In the void between the top wheel and the contact wheel is where the platen will go. It's just going to be a piece of 2 inch angle iron. Cut the end partially then bend the top down. Doing this on both ends.


Then bolt that to a bracket that then bolts the the verticle 2x6. Tada!!!

Obviously there was more than that, that went in to building it. I don't think you guys would care to hear about all the screw ups along the way...

Here's another image for ya...


I know the whole thing seems kind of crude, but since I am still unemployed I can't justify spending $1500.00 on a real one. Besides I think this is going to work out great.

Let me know what you guys think or if you see any designs flaws. I'd love to hear about them.

If you have any questions please feel free...

Chris Nilluka
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  #2  
Old 04-28-2005, 09:19 PM
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Very nice. Good job. I am sure the bugs will work out as you use it.


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Old 04-28-2005, 11:11 PM
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Mike Routen Mike Routen is offline
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Hey Chris,

That is absolutely genius! I love the use of available parts and the simple design! I have no doubt that this grinder will pay for itself in no time and it will really speed things up for you.

If you have trouble keeping the belt centered on the top pulley, just give it a couple of wraps of electrical tape in the middle of the pulley to create a small "crown" and that will keep the belt centered.

Again, well done!

- Mike :-)


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Old 04-28-2005, 11:18 PM
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Quote:
Originally Posted by Mike Routen
If you have trouble keeping the belt centered on the top pulley, just give it a couple of wraps of electrical tape in the middle of the pulley to create a small "crown" and that will keep the belt centered.

Actually... the way the aluminum casters were made, if you put them back to back it creates a crown. So, I've already got that part.

Chris Nilluka
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Old 04-29-2005, 07:06 AM
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Sweany Sweany is offline
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That's just nifty. I it when people just build one instead of whining about the money thingie.

Build what you can afford sell knifes until you can afford another...



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  #6  
Old 04-29-2005, 11:08 PM
TOM BUCHANAN TOM BUCHANAN is offline
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great job,chris.wonder if they sell a 10 inch?


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  #7  
Old 04-30-2005, 12:04 AM
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If I remember correctly these wheels come up to a 12 inch...

Chris Nilluka
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Old 05-06-2005, 04:54 AM
gb6491 gb6491 is offline
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Thumbs up

Chris,
Outstanding work! I like the design and use of materials very much.
Would it be ok to post the pictures in an MSN group about home built grinders (http://groups.msn.com/HomeorshopmadeGrinders)?
Regards,
Greg
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  #9  
Old 05-06-2005, 10:56 AM
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chrisinbeav chrisinbeav is offline
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Update

Yeah Greg...

That's not a problem. If you like I can post a picture or two of the finished product? I have the platten on it and everything. Works awesome!

Chris Nilluka

Okay so here's an official update on my grinder as it is now done and working. I'll show you the completed project first...






The top bolt on the adjustable head is now replaced and works as it should. The first major issue that I have found is that this thing is really loud! I have to wear my earmuffs. However, the more I use it the quieter it seems to be getting, either that or I'm starting to go deaf...

The belt seems to track pretty true. It did wander a bit at first. Even though the casters being back-to-back created a crown, it appearantly wasn't enough. So, as Mike had suggested I wrapped a the top caster a couple times with electrical tape. That help immensly. Other than that, everything seems to be working good. I haven't blown any circuit breakers or anything yet... so that's a good thing. The motor doesn't seem to get too hot when ran for long periods..... So, all-in-all I think it's going to work out nicely!

Chris Nilluka

Last edited by chrisinbeav; 05-07-2005 at 09:12 PM.
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  #10  
Old 05-06-2005, 07:46 PM
gb6491 gb6491 is offline
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Thanks Chris, I posted the photos in an album and included your descriptions of the work.
The platen looks pretty good.
Regards,
Greg
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  #11  
Old 05-08-2005, 05:47 AM
obe obe is offline
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Thumbs up nice job

Hi, nothing like good ole yankee ingenuity. C.J. OBrian
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  #12  
Old 05-11-2005, 01:48 PM
oldfooter oldfooter is offline
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Where did you get your contact wheel. (web site)?
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  #13  
Old 05-11-2005, 05:37 PM
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Quote:
Originally Posted by oldfooter
Where did you get your contact wheel. (web site)?
http://www.bulldogcaster.com/

Just send them an email and explain exactly what you are after. The one I bought I don't think was not listed on the website.

Chris Nilluka
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Old 05-11-2005, 08:14 PM
TOM BUCHANAN TOM BUCHANAN is offline
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hey chris,does that wheel have ball bearings or roller bearings?


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  #15  
Old 05-11-2005, 08:36 PM
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The wheel came with high speed sealed ball bearings and machined spacers to fit the correct size arbor. With the spacers there was a little play back-and-forth with the contact wheel. So, very carefully and slowly you need to file down the inside edge of the spacers where the two of them meet and butt up together.

Chris Nilluka
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