THE RED GRINDER BUILD
I've had a 2x72 grinder that I've used since 2001, it's a made-from-scrap, two-wheel grinder and has worked well but the time had come when I wanted more from it. I started by researching the various makes and models available to buy and various builds that other folks had done. I then compiled a list of features that I wanted in mine and began searching for plans or designs to follow. The primary frame and build design I chose closely follows D.Comeau's guide here: http://dcknives.blogspot.com/p/2-x-72-belt-grinder.html. He's a good guy and he gladly communicated with me throughout my build whenever I had questions. I highly recommend perusing his website, there's a ton of information there and he's a really smart guy. Instead of re-working the existing grinder, I figured it would be beneficial to have a second one in the shop and there's no question that having a grinder helped to make another one a much easier process. I also had access to a welder (which I'd never used) so I knew I could make a decent frame if I put my mind to it.
I had a budget of around $1000 and I wanted the following features in my second 2x72 grinder:
Sounds like a tall order for $1000, right? Getting all of these features in a ready-to-order grinder for that cost isn't possible but it is if you decide to build. I've put together some pictures I took along the way and compiled a list of most of the components I used and where possible, links to them. I used all new steel which was pre-cut by mysteelyard.com which was a pretty big time saver. I'm sure you could cut costs further by obtaining scrap steel and or cutting it yourself. I wanted new steel and also wanted to avoid cutting where possible so this worked well for me.
NOTE: I had zero experience with welding and had never wired a 220v circuit before, both of which were necessary for this project. I took my time with learning both welding and how to run a 220 circuit and made sure to be very careful so as not to electrocute myself. I highly recommend getting an electrician to help with the circuit and VFD wiring if you are not comfortable tackling those parts of the project yourself.
Photos here:
http://s594.photobucket.com/user/derekmelton/Grinder%20Project/story
Parts:
All frame steel & aluminum for tool rests, pre-cut to the right lengths and ordered from mysteelyard.com $130.25
Total so far: $962.52 (all prices include shipping to my home where applicable)
That's just under my $1000 budget for a VERY capable grinder. To put this in perspective, a KMG grinder with 3 pulley speeds (not VFD) a 1.5hp motor and ONE tool arm will run you $1,276.50, plus 39$ switch kit and shipping costs ($100-$150.) Of course, that does not take labor and time into account, you will have to determine whether or not you have more money than time and what your effort is worth. =)
Expenses I incurred but did not 'count' in the cost of the grinder were the wiring, breakers, outlet boxes and associated parts for the new 220v circuit that I had to install in my shop to support the motor & VFD. Not everyone will need to do this so I don't include it in the total grinder cost. I also built the sturdy table you see in the slide show but that was made from scrap treated lumber that I already had on hand.
Things left to do:
Build the contact wheel attachment
Fine tune tracking, there is a very slight amount of play in the vertical tracking tube that's giving me some issues but nothing that won't get fixed. I may possibly change the tracking from plunger style vertical tube to a more traditional horizontal pivot.
Clean up wiring and mount external on/off/speed control switch box.
Take a final "after" pic and post it here. =)
Hope this helps someone, it's been a fun project.
Derek
I've had a 2x72 grinder that I've used since 2001, it's a made-from-scrap, two-wheel grinder and has worked well but the time had come when I wanted more from it. I started by researching the various makes and models available to buy and various builds that other folks had done. I then compiled a list of features that I wanted in mine and began searching for plans or designs to follow. The primary frame and build design I chose closely follows D.Comeau's guide here: http://dcknives.blogspot.com/p/2-x-72-belt-grinder.html. He's a good guy and he gladly communicated with me throughout my build whenever I had questions. I highly recommend perusing his website, there's a ton of information there and he's a really smart guy. Instead of re-working the existing grinder, I figured it would be beneficial to have a second one in the shop and there's no question that having a grinder helped to make another one a much easier process. I also had access to a welder (which I'd never used) so I knew I could make a decent frame if I put my mind to it.
I had a budget of around $1000 and I wanted the following features in my second 2x72 grinder:
- Sturdy, durable and preferably a little quieter than my current grinder.
- High quality wheels and bearings.
- Removable tool arms with 3 attachments: flat platen attachment, 8-10 inch contact wheel attachment and a small wheel attachment.
- 2HP or better direct drive motor with VFD
- Horizontal mode, the ability to flip or turn the grinder on it's side and use a wide tool rest for horizontal grinding.
Sounds like a tall order for $1000, right? Getting all of these features in a ready-to-order grinder for that cost isn't possible but it is if you decide to build. I've put together some pictures I took along the way and compiled a list of most of the components I used and where possible, links to them. I used all new steel which was pre-cut by mysteelyard.com which was a pretty big time saver. I'm sure you could cut costs further by obtaining scrap steel and or cutting it yourself. I wanted new steel and also wanted to avoid cutting where possible so this worked well for me.
NOTE: I had zero experience with welding and had never wired a 220v circuit before, both of which were necessary for this project. I took my time with learning both welding and how to run a 220 circuit and made sure to be very careful so as not to electrocute myself. I highly recommend getting an electrician to help with the circuit and VFD wiring if you are not comfortable tackling those parts of the project yourself.
Photos here:
http://s594.photobucket.com/user/derekmelton/Grinder%20Project/story
Parts:
All frame steel & aluminum for tool rests, pre-cut to the right lengths and ordered from mysteelyard.com $130.25
- A500 Steel Square Tubing - 1-1/2 x 1-1/2 x 3/16 Custom Cut Length: 1' 5"
- A500 Steel Square Tubing - 1-1/2 x 1-1/2 x 3/16 Custom Cut Length: 1' 1"
- A500 Steel Square Tubing - 2 x 2 x 3/16 Custom Cut Length: 10"
- A500 Steel Square Tubing - 2 x 2 x 3/16 Custom Cut Length: 4"
- 6061 Aluminum Flat Bar - 1/4 x 5 (three) Custom Cut Length: 1'
- Hot Rolled A36 Steel Flat Bar - 3/16 x 2 Custom Cut Length: 4' (will use for reinforcing, possibly re-working tracking arm later)
- A500 Steel Square Tubing - 2 x 2 x 3/16 Custom Cut Length: 3' (I added this section later, cut it myself for more tool arms)
- Complete high quality aluminum wheel set (4 wheels) & small wheel attachment with two rollers (1 inch and 1/2 inch) came from KnifeGrinderParts.com, $225 for all.
- Oregon Blade Maker D shaped-backing plate for 2x72 platen assembly with 1/2 inch bolt axles and nylon washers $50.75
- 2hp tOSHIBA TEFC Motor & TECO L510 VFD from dealers electric $326.52 http://dealerselectric.com/2HP-3600RPM-230Volts-Input-Package.asp
- 10 inch contact wheel 150$ http://www.ebay.com/itm/201590217512?_trksid=p2055119.m1438.l2649
- Miscellaneous nuts, bolts, washers, springs, external switches, etc. $60
- Ceramic Glass platen $20
Total so far: $962.52 (all prices include shipping to my home where applicable)
That's just under my $1000 budget for a VERY capable grinder. To put this in perspective, a KMG grinder with 3 pulley speeds (not VFD) a 1.5hp motor and ONE tool arm will run you $1,276.50, plus 39$ switch kit and shipping costs ($100-$150.) Of course, that does not take labor and time into account, you will have to determine whether or not you have more money than time and what your effort is worth. =)
Expenses I incurred but did not 'count' in the cost of the grinder were the wiring, breakers, outlet boxes and associated parts for the new 220v circuit that I had to install in my shop to support the motor & VFD. Not everyone will need to do this so I don't include it in the total grinder cost. I also built the sturdy table you see in the slide show but that was made from scrap treated lumber that I already had on hand.
Things left to do:
Build the contact wheel attachment
Fine tune tracking, there is a very slight amount of play in the vertical tracking tube that's giving me some issues but nothing that won't get fixed. I may possibly change the tracking from plunger style vertical tube to a more traditional horizontal pivot.
Clean up wiring and mount external on/off/speed control switch box.
Take a final "after" pic and post it here. =)
Hope this helps someone, it's been a fun project.
Derek
super clean build
