Making a Metabo Burnisher

[Whiskeymike]

I'm looking to make a Metabo Burnisher like this -

from a grinder, a spindle made on a lathe and a guard and handle fabbed up that will attach to side of grinder. Why? I can't justify the $600-700 price tag as I won't use it all that much. And I also need a project to work on the lathe.

Does anyone have one of these as I'm looking for a picture of the spindle that comes with it and haven't been able to find decent photos online or in videos. I plan to turn down a steel rod and thread the end to attach to the grinder, with the other end accepting a nut to hold on the abrasive wheel. I assume the abrasive wheel is free spinning on the spindle, but the end nut is compressing it together to provide force to keep it in place?

I'll then weld up a guard similar to what's shown on the product.

I plan to use a variable speed grinder as the RPM is much lower on this than a typical grinder.

Any advice on the construction before I get too deep?

 

[kkroger]

Camel Grinding Wheels sells the "Flex" Brand Arbor for that, you just screw it on the spindle...
then all you need is a more appropriate side handle..

http://www.cgwcamel.com/datasheet/44.pdf

 

[LXCam]

Camel Grinding Wheels sells the "Flex" Brand Arbor for that, you just screw it on the spindle...
then all you need is a more appropriate side handle..

http://www.cgwcamel.com/datasheet/44.pdf

That's awesome, I gots to gets me one of dem.


I've always struggled with either using my 6 X 48 belt sander with a scotch bright belt or the same thing with my belt grinder. And trying to keep straight lines is like pulling teeth. And like the OP, I never wanted to spend that kind of money for something that rarely get used.

Thanks for the link K.

 

[Whiskeymike]

That's awesome! thanks for the link. Now I have to find another project for the lathe, but it makes this a lot easier.

 

[Gamble]

That's awesome, now I need one. Don't see where to order online though

 

[e36jon]

Pay attention to the speed limitations for the media that you plan to use with your mod: They aren't rated for the typical 13-15k rpm of an angle grinder. The Metabo and similar burnishers run at 2.5-3.4K rpm. That also has implications for the torque rating of your grinder (Those wide flap wheels generate some impressive torque!)

I ended up buying a Metabo to do a single project (stainless steel fence) as I couldn't figure out a less expensive way to do what I needed to do...

Cheers,

Jon

 

[e36jon]

Oh yeah, I didn't pay $800 either. A 'mere' $579.99 from Amazon with a nice steel case and a bunch of media...

https://www.amazon.com/gp/product/B0019I9224/?tag=atomicindus08-20

It never blinked after burnishing several hundred feet of square stainless tubing. That said, I didn't love the ergonomics. If I had to do it over again I would look for one of the 'polisher' style tools with the longer body and smaller grip.

Sorry if that's TMI...

 

[Guster]

Is this what you are after? Post #2414:
http://bbs.homeshopmachinist.net/threads/39202-Shop-Made-Tools/page242

It is on my list of things to make later this year as I have enough grinders. I would rather buy another 2or3 grinders than buy a purpose built burnisher for 10x the cost and rarely use. The only issue with using a grinder is that burnishers have speed control and many of the burnishing media need to run at slower speeds. I like using the flap disc style burnishers that have 3M pad and sandpaper or abrasive bristles. They can run at higher RPM and have a slightly coarser finish but can be used on diamond plate and really dirty sheetmetal so can be used for cleanup and burnishing which means I can use it more often. I really like the idea of being able to polish tubing too.

 

[dr_clyde]

I have the metabo burnisher. If you decide to make one, be certain you get an adjustable speed grinder, they are not a standard speed. They go much slower, and need to be variable due to the different kinds of abrasives.

Metabo sells the base grinder as the Inox series one iirc.

 

[Whiskeymike]

Is this what you are after? Post #2414:
http://bbs.homeshopmachinist.net/threads/39202-Shop-Made-Tools/page242

It is on my list of things to make later this year as I have enough grinders. I would rather buy another 2or3 grinders than buy a purpose built burnisher for 10x the cost and rarely use. The only issue with using a grinder is that burnishers have speed control and many of the burnishing media need to run at slower speeds. I like using the flap disc style burnishers that have 3M pad and sandpaper or abrasive bristles. They can run at higher RPM and have a slightly coarser finish but can be used on diamond plate and really dirty sheetmetal so can be used for cleanup and burnishing which means I can use it more often. I really like the idea of being able to polish tubing too.

That's exactly it! Thanks for the link. I really like what he did with the handle. The spindle looks sharp as well. Definitely saving that one.

I ordered the CGW spindle from eBay - Gamble, you can find it here - http://www.ebay.com/itm/111989278143?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT

It was about $20. I found it elsewhere for $10, but had to sign up, and didn't know what they would charge for shipping, so decided to keep it easy on eBay.

I'm thinking about getting the Metabo WEV15-125 Quick which is 13.5amp, 31 inch pounds of torque. The high torque model is a bit cheaper and gains 5-6 inch pounds, but I didn't think it would make enough difference. The variable speed on the Quick is 2800-11000 RPM and maxes out at 9600 on the HT. The INOX is a bit more $$, but brings the torque up to 44 inch pounds but RPM down to 7600 rpm. Not sure the trade off when I would use it for flap discs and the wheel. Too many options!

Originally, I was planning on trying it out on an 8 amp HF grinder and using a router speed controller from HF which seems to work okay with the grinder. But decided this was good excuse to get a nice grinder that I can use for anything.

I ordered a couple 4x4 metabo wheels to try out on the CGW spindle so I should be able to try it next week. I haven't ordered the Metabo as I'm trying to find a Zoro coupon or a decent deal on the Metabo. At $250, a 20-25% coupon would be a nice chunk.

 

[paranoid56]

Is this what you are after? Post #2414:
http://bbs.homeshopmachinist.net/threads/39202-Shop-Made-Tools/page242

It is on my list of things to make later this year as I have enough grinders. I would rather buy another 2or3 grinders than buy a purpose built burnisher for 10x the cost and rarely use. The only issue with using a grinder is that burnishers have speed control and many of the burnishing media need to run at slower speeds. I like using the flap disc style burnishers that have 3M pad and sandpaper or abrasive bristles. They can run at higher RPM and have a slightly coarser finish but can be used on diamond plate and really dirty sheetmetal so can be used for cleanup and burnishing which means I can use it more often. I really like the idea of being able to polish tubing too.

well there went my day looking at all these shop made tools lol

 

[Gamble]

let us know how it works out for you!

 

[Guster]

well there went my day looking at all these shop made tools lol

Hehe... you like? I know where to find more forum posts like these too.

Worst is trying to find something you saw in one of these ages ago. You get to go through the whole lot all over again!

 

[Whiskeymike]

let us know how it works out for you!

So I bought a Metabo Inox grinder(similar grinder base used in the burnisher, variable speed, high torque), and the arbor listed above, plus a couple metabo wheel drums. I assembled it today and it works quite well.

I ran in to two issues. First, the spindle is a tad wide for the wheel drum. I addressed that with a couple washers and it holds the drum on fine. Second is the width of the spindle, especially on the bolt half is narrower than the hole of the metabo wheel drum. So when tightening the spindle, it has a tendency to be off center. I may still go ahead and make a new on on the lathe that fits better. But I was able to get it centered well enough for testing.

I tried using it to strip mill scale and dross and it worked so so. It cleaned it up, but it was a fair bit slower than flap discs. But I think that it had to more to do with abrasive count than anything. The lowest wheel drum I bought was 80 grit and my flap discs are 40. So unfortunately, that didn't work out, but I'll look for more aggressive wheels and try again.

Now for finishing, this thing is a dream. After cleaning up a piece of 16 gauge, I ran it over with this in a couple straight passes and it came out wonderfully.

So overall it's been a success getting a burnisher for about $300 including the wheels, instead of $600 for the ready to use model. Best thing is that I can use the grinder with flap discs as well. So it's a much more versatile solution for me.

 

[zkling]

Interesting...I've looked into them before, but never really needed. A 7/9" variable speed buffer would get you in the right speed and power range compared to a grinder. What is the cheapest source of wheels?

 

[kkroger]

You really don't need one until that time you DO... then you will pay out the **** for it!!!! Ask me how I know!

I like the Flex one personally smaller lighter motor. We have a knockoff and a Flex here at the shop. I need to replace my tube and pipe polisher with a Flex Boa...

 

[Whiskeymike]

The Metabo wheels are the cheapest I've found at about $25-$45 each on Amazon. I've checked my normal sites for abrasives and they either don't make them or are a fair bit more expensive. If anyone has better sources, please let me know.

I'm curious to see how long they last.

 

[kkroger]

Check E-bay, the business partner gets them from E-Bay all the time and about half the price of "Others" but they are of Chinese origin, CGW from Roarke Supply is about $35 a drum and Made in USA...