Couple questions. I put wire wheels on one; how do you hold the shaft to tighten the nuts?
I actually use a low-power electric impact. The shaft still spins, but the impacting force turns the nut more quickly than the shaft if you hit it in short bursts, same for undoing it.
One that has grinding wheels, bogs down very easily. I am dumb about electrical stuff.
1/4 should bog a little under load. 1/3 should not unless you're really going to town on a coarse wheel, which would suggest one of two things. Either you're getting poor power to the stator, or you're losing a lot of your motor's energy in bad bearings. Depending on how old the unit is, replacing the capacitor and bearings will make the machine like new.
Capacitors, get an american made one from either Aerovox, Am-Rad, or Mallory. Mallory isn't in the game anymore but it's really easy to find NOS. You can order direct from Am-Rad and Aerovox has distributors everywhere but their CSRs have their heads up their asses.
Bearings there are three good options, shown in order of goodness here: German made *** (rofl) bearings, japanese made bearings of any brand, specifically Nachi (but they're all good), or argentinian made SKFs that can be picked up at your local bearing supply.
Can someone take one of these things apart and describe how they work/how to fix common ailments?
There isn't a whole lot to a grinder, I'll break it down here. What you have is a ultra-typical electric motor, which is a round stator with several yards of wire wound circularly around it which creates a rotating electromagnetic field when turned on and an armature (or "rotor"), which is a magnetic metal barrel that sits exactly in the center of the stator with a tiny few mm clearance all the way around. When the stator creates its spinning field, the armature "chases" the field in a circular motion trying to connect electromagnetically. Since it is always held away from the surface of the stator by a few millimeters, it never connects and just continues to spin and spin and spin as long as the stator has power, forever locked in a perpetual chase game of electromagnetic cat and mouse.
The armature is held in place through the center of ball bearings which keep the armature exactly in place never touching the stator, and allow the whole works to spin. Wheels and brushes are attached to the end of the spindle (the rod that runs through the armature and bearings) the take perpendicular-advantage of the spinning motion.
So here's, literally, all the parts of a grinder:
1) Stator
2) Rotor
3) Capacitor
4) Switch
5) Bearings
6) Body castings.
Of those pieces, there's only a few things that can go wrong and they all have a protocol for fixing.
1) Stator: wiring can break, corrode, or just generally fail. This is a death sentence for most any grinder worth less than $1000 because a full rewiring and rebuild is required and isn't cheap. This type of failure is extremely, extremely rare (like once every 100 years rare for the good brands). Symptoms: grinder doesn't work at all. Sometimes smoking from motor.
2) Your capacitor can blow. This is mega common, and extremely easy to fix. Capacitors are under $10 and can be installed with nothing more than a crimper and a screwdriver. Symptoms: Low power output, no power output, buzzing, humming, or smoking from base.
3) Your switch can fail. Buy a new one. Somewhat rare occurrence. Symptoms: low or no power response.
4) Your bearings can fail. Buy new ones for less than $10 each. Somewhat rare but totally plausible. Symptoms: Excessive heat at the spindle, excessive noise at the spindle.
5) You can get **** build up in the airspace between the rotor and stator. Corrosion or dust or grease or **** or god knows what get get inside cheaper grinders and degrade the function of the armature by creating friction. Symptoms: Excessive heat at the motor. Excessive noise at the motor.
Boom. Benchgrinder clinic 101. It really is that easy. There's like 6 parts in total, only 4 of which can fail, and all can be fixed. It's literally so simple a child could work on one with proper pictures and guidance. Here's some photos from a recent resto of mine.
Stator with armature inside. Visible is the wiring of the stator, the armature spindle, and bearings.
<a href="http://imgur.com/Atovj"><img src="http://i.imgur.com/Atovj.jpg" title="Hosted by imgur.com" alt="" /></a>
Close-up of armature within stator:
<a href="http://imgur.com/4Isiv"><img src="http://i.imgur.com/4Isiv.jpg?1" title="Hosted by imgur.com" alt="" /></a>
Stator with armature removed:
<a href="http://imgur.com/Al7Xj"><img src="http://i.imgur.com/Al7Xj.jpg?1" title="Hosted by imgur.com" alt="" /></a>
Armature with spindle and bearings:
<a href="http://imgur.com/lIqar"><img src="http://i.imgur.com/lIqar.jpg?1" title="Hosted by imgur.com" alt="" /></a>