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New 2 X 72" Grinder Build

Discussion in 'Grinders' started by dancom, Jun 4, 2017.

  1. dancom

    dancom Dust Maker Best Shop Tool

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    I was thinking the same or some thin nylon washers. It may about see 3000 RPY (Revolutions Per Year!)
     
  2. John Noon

    John Noon Well-Known Member

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  3. dancom

    dancom Dust Maker Best Shop Tool

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    I have 0.505" ID nylon washers from McMaster-Carr for the idler wheel spacers. Could use them in multiple places.
     
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  4. ToddR

    ToddR Active Member

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    Dan, you mentioned the price you paid for your motor but, unless i'm really blind, i can't find where you got it. Do you remember, off hand, where you bought it from? Also, where do you get the vfd, if i can ask. I'm moving into a new house on the 30th and I'm going to have an electrician add a couple of new circuits. I'm thinking of also putting in a 50A receptacle for a bigger welder (down the line - wink) and whatever i'd need for a better grinder motor. Sorry, i'm not very good with electrical terms and science.

    Thanks Dan. And again, crazy cool grinder. I really can't believe you put this together for anybody to use, no welding, low cost, free. Really great.
     
  5. dancom

    dancom Dust Maker Best Shop Tool

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    Hi Todd,

    The motor is from Automation Direct and came to me with free shipping. It was US$152.00. All freight, duties were included which ended up being $213 Canadian. The model number is MTRP-002-3BD36.
    The VFD I am using is a Huanyang 2.2kW I got from Amazon.ca. Ok it's not the fanciest VFD, but it will be tucked away in a box and remote control brought out to the grinder.
    To supply the electrical you will want a 240 volt 15 ampere circuit. One that looks like this -.- A 20 ampere circuit would work as well.

    By the way, it's only fair to let everyone know. Everything I have bought for this project has been paid for from revenue that was generated by advertising on my blog. Yes, it's taken a while. But in this way I am giving it back to the community. My time and passion are...free.

    ;-)

    Regards,

    Dan
     
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  6. dancom

    dancom Dust Maker Best Shop Tool

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    Some checks...

    I wanted to tighten the tension arm pivot bolt to a firm state, but it can still be moved with a force that's close to the force the spring is at. Then check the side play in the tension arm at the tracking hinge. A dial indicator with a magnetic adjustable base is used to measure the play. Line it up against the arm and press it left and right with a reasonable amount of force. I'd say 5 lbs.
    [​IMG]

    With the oiled leather 3 oz washers and good firm squeeze the side play was about 0.015" (0.38 mm). It seems like there is more flex in the steel tracking arm that in the pivot.


    On the backside there is a place to install a cable mount or saddle. The power cable going to the motor will be anchored with a cable tie there. When the frame rotates, the motor power cable needs to be secure and away from pinch points.
    [​IMG]



    [​IMG]

    Restricting the airflow to the motor can cause the motor to overheat. Yes and restricting the airflow and slowing the motor down with the VFD is quadruply dangerous. You have to leave some space around the fan for air to get to the motor.

    ---------------

    After some thought...the one major issue I have with this design is that the how long the motor is, really matters. The Ironhorse is a stout motor at around 9.625" from the face to the rear end.
    With the tilting design, not only does the motor have swing through the arc and clear the base, but there has to be some airflow clearance around the motor's fan when the motor is positioned vertically. At minimum 1" of space is recommended. Longer motors will require taller frame mounts. If you have a motor that's 11" long, some 2" taller frame mounts are needed.

    [​IMG]

    Kijiji proved fruitful once again. I picked up a 12" x 16" x 7" Hammond steel NEMA 1 enclosure. Now to began to layout the electrical parts. I did come calculations for heat and I do need a fan to extract the heat from the enclosure.
    [​IMG]

    My wheel set is in Ohio according to the tracking info.

    Next is the flat platen accessory.

    Dan
     
    Last edited: Jun 16, 2017
  7. Kevin Cox

    Kevin Cox KC knives

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    It's coming along real nice Dan. I really like your tracking arm and how you got your springs.A little side play on the tracking arm shouldn't be a issue.
     
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  8. John Noon

    John Noon Well-Known Member

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    You could do a cutout in the base of the grinder and a matching hole in the work bench would get you all the airflow you need.
     
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  9. dancom

    dancom Dust Maker Best Shop Tool

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    I got around to making the flat platen and checking the pivot mechanics. All seems to be going well. Still waiting on the hardware coming up from the US.



    The spacing for mounting the platen D plate is 1.25 and 1.25.
    [​IMG]

    The large hole is 5/16" and tapped to 3/8" NC the small hole is 13/64" and tapped to 1/4" NC.
    [​IMG]

    I cleaned out the holes with a brush to get any aluminum out that my cause galling.
    [​IMG]

    The fit is good. The 1/4" bolt shown is temporary as the little adjustable handle is still in shipping.
    [​IMG]

    To space the wheels off the D plate I need 1/4". I have some 1/2" jam nuts on the way, but these spacers made from schedule 40 3/8" pipe will work in the meantime.
    [​IMG]

    Using the 4x36 and a handheld magnet to get the faces of the spacers parallel.
    [​IMG]

    And thar she is. This week I will have the drive wheel in and will be working on the electrical design of the universal work rest.
    [​IMG]

    Thanks for watching. Happy Father's Day to all the dads out there.

    Dan
     
  10. ConnorBC

    ConnorBC Active Member

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    Spending your Fathers Day building cool tools... That's a damn fine Fathers Day right there! It's really coming together nice! :)
     
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  11. Kwesi

    Kwesi New Member

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    Happy Father Day Dan and all the Fathers out there. Dan the pivot mechanics came out nicely. Are those indexable locking handles easy to get in Canada?
     
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  12. dancom

    dancom Dust Maker Best Shop Tool

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    Thanks! Went to the movies with the family.

    You can get indexing handles through Fastenal. I just ordered them along with a bunch of hardware from McMaster-Carr, bit the bullet on freight and exchange and came out slightly ahead.
    If you plan for it, one shipping charge is much less than spending hours looking and driving around for hardware. McMaster-Carr has everything.

    Dan
     
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  13. parker

    parker Active Member

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    It's actually crazy what McMaster Carr has. For industry needs pretty much dream it up and they carry it haha
     
  14. dancom

    dancom Dust Maker Best Shop Tool

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    Thinking of this for the VFD remote control at the topside.

    [​IMG]

    The idea is that a page can be printed to mark and drill and another can be printed as a label using Duralabel.

    Dan
     
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  15. Kwesi

    Kwesi New Member

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    Thank you, Dan and Parker. I will check out McMaster Carr.
     
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  16. dancom

    dancom Dust Maker Best Shop Tool

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    I don't know how they do it, but McMaster-Carr is literally an "order today and it arrives tomorrow" kind of place. I ordered some fasteners for work at 11:00 AM yesterday and they arrived at 9:30 this morning!
     
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  17. Kwesi

    Kwesi New Member

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    Wow..Dan that is justlighting fast in Canada.
     
  18. dancom

    dancom Dust Maker Best Shop Tool

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    Not all things could be water jetted and a few parts need to be fabricated. I was able to get the platen and brakets made last night.

    I made the platen brackets out of heavy 2" angle and slotted a 1/4" x 1" hole for adjustment. Also, one hole in each bracket is drilled and tapped to 1/4"-20 to mount the platen.
    [​IMG]

    The platen itself is plain old 1/4" x 2" stock at 9-1/2" long. I scribed a line down the centre and drilled countersink bored 5-1/2" on centre,
    [​IMG]


    The mounting screws are 1/4"-20 x 3/4" flat heads that should sit close to flush with the surface when tightened.
    [​IMG]

    Note that the mounting holes in the bracket are offset by 1/4". This puts the left side of the platen in line with the left sides of the wheels.
    [​IMG]

    As the platen runs a little bit proud, I chamfered the ends of the platen to reduce the drag on the back of the belt.
    [​IMG]

    Now to break it down and paint the brackets.

    Maybe there are better way of doing this. I was pondering tapping the platen itself and screwing in from behind. That would mean that replacement platens are a bit more effort to make. Also there could be a ledge for resting a pyroceramic platen. That would have to be drill and tapped on. Then again, maybe simple is good.

    Thanks for looking,

    Dan
     
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  19. ConnorBC

    ConnorBC Active Member

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    Looking good Dan! Can't wait to see it painted and installed. Its sure coming together. :)
     
  20. dancom

    dancom Dust Maker Best Shop Tool

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    Next is the work rest. Still working out the table tilting.

    Unfortunately my wheels via eBay Global Shipping went from the US west coast, to Kentucky, to Mississauga and are now heading back west. Last I checked they were in Winnipeg. I was hoping to have them today and get power to this thing. Well there are lots of little things to do in the meantime. The VFD is wired and the remote control box need to be finished.

    I put up a page yesterday: http://dcknives.com/osg/
    You can add your name and email if you want to be notified when the files are available. In the contact form there is a selection which says "No, I am unable to help" or "Yes, I can help". To my surprise 75 % of the submissions are willing to help in some way.

    Amazing eh?

    Dan
     
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