About the project
How much does it cost to build?
It ranges from about $700 to $1700 US, depending on the motor & VFD you choose, and which attachments you build. If you want just the basic machine (power unit, platen attachment, table holder, & fixed table) with a cheap single-phase motor and no VFD, you can build that for about $700. Add about $200 if you want a high-quality motor. Add $350 if you want a VFD (for variable speed). Add about $170 for the Contact Wheel Attachment with a 10″ wheel, about $250 for the Small Wheel Attachment with a few wheels, and about $30 for the Adjustable Angle Table. The machine in the build video cost me $1700, with all the attachments. (Based on 2021 prices in the US)
What tools are required?
A welder, angle grinder, and drill press are the only required power tools. A bandsaw saves a lot of time, but is optional. Non-power tools include a combination square, clamps, wrenches, a hacksaw, files, a center punch, drill bits, and a 3/8″ or M10 tap.
How long does it take to build?
This will vary drastically from person to person. That said, I kept track of my time building my first prototype of Gen 2, and it took me 28 hours to build the power unit, 4 hours to build the platen attachment, 6 hours to build the table holder, and 2 hours to build the fixed table, for a total of 40 hours. These times include everything from cutting raw materials to painting & testing. Keep in mind that this was the first prototype, so I did not have plans to follow.
What materials & hardware will I need?
The plans include a detailed shopping list and cutting list, but you can click here for a shopping list to see what’s required.
I have access to a CNC plasma / laser / waterjet. Can I get drawings for CNC cutting?
Yes, I offer 2D DXF vector drawings of all the 3/8″ & 1/8″ (8mm & 3mm) flat parts. These files are included with your Gen 2 Belt Grinder plans.
Can I use square tube for the frame tubes, rather than making them from flatbar?
Yes, but I discourage this. Consider that 1) you will need to remove the seam from the square tube and chamfer the corners of the tool arms to fit inside the square tube, so getting the tool arm to fit the square tube will likely take longer than just making a custom tube. And 2) the tool arm will fit in the custom tube much more precisely, making your grinder perform better. I made a video comparing these options in depth, which you can watch here.
Can I buy the machine pre-made / hire you to make it for me?
Unfortunately, no, I don’t make them for sale. I think you’ll find that with the help of the plans, the project is easier to complete than you might expect, and the required tools are still cheaper than buying a pre-made grinder. But if building it is not an option, you’re best off to take the plans to someone who can build it for you.
Where can I see other people’s finished grinders?
I’ve created a webpage just for sharing photos of belt grinders built by you, my viewers. See it here.
About the machine
Can it use 50 x 2000mm belts?
Yes. The metric version of the plans includes instructions to make the frame longer to fit 50 x 2000mm belts. However, it cannot use both 2 x 72″ and 50 x 2000mm belts, you must choose one or the other.
How big of motor do I need?
I recommend at least 1.5hp (1.1kW). I used a 2hp (1.5kW) motor on mine. If possible, use a VFD for variable speed. If you’re using a VFD, you can start with a ~1800 RPM motor and overspeed it to get a higher belt speed, but still have good torque at low speed. The plans include an entire page about motors & VFDs, so reference that for more info.
How big is the machine? (Will it fit on my workbench?)
Click here to see a diagram with dimensions, showing how much space you need for the grinder to work in both orientations. The overall height of the machine is 25″/645mm to the top of the tensioner handle.
How heavy is it?
- Power Unit: 56 lbs, 101 lbs with recommended motor
- Platen Attachment: 16.5 lbs
- Table Holder: 16.5 lbs
- Fixed Table: 8.5 lbs
- Adjustable Angle Table: 10 lbs
- Small Wheel Attachment: 16.5 lbs
- Contact Wheel Attachment: 9.5 lbs (without contact wheel)
What is the belt speed?
This machine is designed to use a 5″ or 130mm drive wheel, which has a circumference of 1.31 feet. So you can multiply motor RPM by 1.31 to get surface feet per minute (SFPM). In the case of my grinder, my motor runs 3970 RPM, so I get 5200 SFPM.
Are the attachments backward compatible with Gen 1?
No. The tables are backward compatible, but the table holder, platen, small wheel, and contact wheel attachments are not. This is because the position of the main hinge has changed, so the Gen 2 attachments would not be centered on the hinge of the Gen 1 grinder.
If your questions were not answered here, please contact me. I will add the most common questions to this page.