Home Made 2x72 Belt Grinder

[millsrv]

Hi Everyone,
I just finished a fun project that all started after I built a small foundry for melting aluminum (thanks YouTube for the ideas). The foundry is another subject but it allowed me to pour the aluminum (melted scrap I had) that I needed to make the pulleys for my 2x72 belt grinder. I used steel bean cans for molds and did the machining on my Atlas 6x18 mini lathe. I scavenged a 1-1/2 HP motor from an old air compressor, the bearings are mower deck bearings from Ebay, and the steel I had.
Total cost including belts under $100. Total time, I lost track, at least 40 hours, but I'm retired so it does not count, LOL. I watched many YouTube videos as they tend to inspire me. There are some very talented folks out there nice enough to share their ideas.
I wanted to build this machine as much as possible from what I had, and I pretty much did just that.
The grinder is up and running and exceeding my expectations, I have really bonded with the machine. I currently am making other attachments.
Attached are a few pictures.

 

[millsrv]

Some additional pictures.

 

[Mario428]

Nicely done

 

[LXCam]

Excellent job. I can't really tell from the pics (on my phone) but what did you do for belt tensioning, spring or fixed?

Scratch that, I see the weights and cantilevered arm n pulley.

 

[millsrv]

The tensioner arm is weighted by three 5 pound workout weights and there is also a light spring. My experience is that finding the correct tension is kind of trial and error but having it correct is important not only for belt life but also for proper tracking.
I did learn that the high quality, very expensive commercial machines are very heavy as mass is important to reduce vibration. This was my mission from the beginning and I had the weights. I have not seen another machine using weights.

 

[LXCam]

The tensioner arm is weighted by three 5 pound workout weights and there is also a light spring. My experience is that finding the correct tension is kind of trial and error but having it correct is important not only for belt life but also for proper tracking.
I did learn that the high quality, very expensive commercial machines are very heavy as mass is important to reduce vibration. This was my mission from the beginning and I had the weights. I have not seen another machine using weights.

Neither have I, nice design. And I completely agree with you about having the mass and being beneficial. I have a burrking and it's the most used machine in my shop.

 

[manwithtools]

Very Nice!

I want so bad to make one of these, but I have WAY to many other unfinished projects to worry about this yet. One's like your's serve as inspiration for the future. Again, great job.

 

[sr71]

Nice Job - I know they are the go-to tool for knife makers but to me, it seems that these 2x72" are a perfect grinder for so many around the shop situations. I have one on my mind as well ..

 

[matt_i]

This is outstanding! I'm impressed what you can do with an Atlas 6". I have a question, are all of the pulleys crowned or do you just need a single one to have the crown to keep the belt tracking straight.

Having that thin edge is so useful in some applications!

 

[Whiskeymike]

Wow! Incredible that you were able to create the pulleys from scratch from foundry and with a mini-lathe. Did you crown the pulleys, was hard to tell from the photos. Very nicely done.

I don’t have the skills or patience you have. Does anyone sell a set of pulleys matched with a variable speed motor that are well paired? I don’t want a complete kit, but I’ve been procrastinating on a motor/vfd, or alternative for 6 months as I don’t want to screw up.

 

[PugetDude]

Nice work! Always like posts about homemade machinery.

 

[millsrv]

This is outstanding! I'm impressed what you can do with an Atlas 6". I have a question, are all of the pulleys crowned or do you just need a single one to have the crown to keep the belt tracking straight.

Having that thin edge is so useful in some applications!

From what I learned on the fly the motor drive pulley and the tensioner / idler pulleys do need to be crowned. I did not crown either at first but found that keeping the belt running centered while grinding was impossible without the crowning of the afore mentioned pulleys. Crowning those pulleys was not easy due to my lack of lathe operation experience, but I managed to get it done. Others have made a jig that mounts to the lathes tool post, for crowning. YouTube has a number of videos on this subject and many were very helpful to me.
The bottom line for me was not to give in and buy pulleys when I could figure out how to make them. I spent a lot of time casting and machining them. One I made from melting an old pressure cooker!
I want to make a rubber contact wheel attachment and doing that is going to be very challenging but that is the fun part.

 

[gahrajmahal]

Ha, ha that is so funny how you credit all the talented makers showing you how to make things on You Tube. I watched a video then poured my own belt rollers in tin cans out of some scrap I had laying around. Of course you did!

You sir have some amazing fabrication chops and your design is fantastic! What are you making with the new sander? Or should I say, what videos have you been watching lately?

 

[millsrv]

Ha, ha that is so funny how you credit all the talented makers showing you how to make things on You Tube. I watched a video then poured my own belt rollers in tin cans out of some scrap I had laying around. Of course you did!

You sir have some amazing fabrication chops and your design is fantastic! What are you making with the new sander? Or should I say, what videos have you been watching lately?

Thanks!
I have been using the grinder for all kinds of metal work. For example, I made a knife out of a worn out file, that was fun and the darn thing is sharp. Sharpening knifes, axes, chisels, grinding welds, shaping metal and wood, just to name a few. It is amazing how useful this grinder is and having a selection of belts from coarse to fine is really needed.

 

[Kaizen]

Matt Cremona on YouTube was just saying he was making one as well and referenced someone on YouTube that sold plans. Was that you??


Sent from my iPhone using Tapatalk

 

[jimgood]

Kaizen, this guy has designs for his and is one of the best I've seen. Millsrv, nice job on yours!

The link to his plans isn't working at the moment but I think it's temporary. I was just there a couple days ago.

 

[steel 35]

Great stuff here
I been draggen my tail as well, Just the kick I needed!

Wait if Heavy is good, I know Just the guy

 

[toolferone]

Kaizen, this guy has designs for his and is one of the best I've seen. Millsrv, nice job on yours!

The link to his plans isn't working at the moment but I think it's temporary. I was just there a couple days ago.

That is Jeremy Schmidt. His is the one Matt Cermona is going to be building. It is a very nice solid machine.

 

[Richard D]

The link to the plans is working now. I already built one of my own, some time ago, handy tool.

 

[zmotorsports]

Very nicely done.