Many of the parts of my belt grinder are rounded over with a radius that is concentric with a hole. For example, all of the hinge parts are like this. When I built the grinder, I used my angle grinder to make these parts by hand, but I really wanted to be able to make better-looking rounded corners in the future. So I designed and built a jig that uses the belt grinder to radius corners. The jig consists of a table with an interchangeable pin that the part can rotate on, and a mechanism that lets me advance the workpiece into the belt. Watch the video below to see how I built it and how it works:

Plans

I am not satisfied with this design. It causes premature belt wear, and it’s uncomfortable and unsafe to use for larger radiuses. If you’d like to build the jig anyway, you can download a free Sketchup model for it below. There are no pdf plans for it, since I’m not willing to sign off on the design.

Sketchup model: Belt grinder radius jig.zip

Note: The .zip file above contains a Sketchup (.skp) file, so you will need to un-zip and extract the .skp file before opening it. You will need the latest version of Sketchup in order to view this model.