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Cut Off Saw from an Angle Head Grinder
by Phil B on February 9, 2009

Table of Contents
Cut Off Saw from an Angle Head Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Intro: Cut Off Saw from an Angle Head Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 1: Basic piece for a start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 2: First step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 3: Weld a base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 4: Weld the hinges to the base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 5: Depth of cut adjustment--part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 6: Depth of cut adjustment--part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 7: Vertical support for the grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 8: Cut the vertical and add a horizontal piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 9: Upper mount for the grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 10: The fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Step 11: The shower of sparks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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http://www.instructables.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/

but I have a bias against most of their tools and wanted to make my own. but you can use other things.Author:Phil B I miss the days when magazines like Popular Mechanics had all sorts of DIY projects for making and repairing just about everything. I had an angle head grinder and wanted to make a mount for it to convert it to a cut off saw. I used scraps of steel I already had. I am enjoying posting things I have learned and done since I got my first tools. I also have a welder. If you choose to make a saw like mine.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/ . a router. For a long time I had no idea how I would make use of this piece. One of these was a piece of 1 inch square tubing about 22 inches long with a 90 degree bend at one end. I ride a bicycle about 100 miles a week for exercise. http://www. I like to dabble with some electronics projects. you probably will not have a piece like I had. a radial arm saw. I enjoy studying the Bible and I am also a Lutheran pastor. Intro: Cut Off Saw from an Angle Head Grinder It is difficult to cut a straight line by hand with thin cut off wheel in an angle head grinder.instructables. You could even weld a couple of pieces of square tubing together to make an "L" shaped piece. I have a lathe. Step 1: Basic piece for a start A friend gave me some scrap pieces of steel. and an arc welder for stick electrodes. I know you can buy a mount at Harbor Freight Tools.

The magnet is visible in the lower right of the picture. Later I added a magnet from a hard drive.instructables. Then I welded two door hinges to the 9 1/2 inch piece. The chip board swelled and I decided to replace it with a steel frame for the base. My welds are not very pretty. lest I burn through the tubing. See the Sketch up drawing to see how the parts are positioned for welding the two pieces of square tubing. http://www. I found it a little tricky to weld the edges of the hinges to the corner of the relatively thin square tubing.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/ .Step 2: First step I cut about 9 1/2 inches from the straight end of the square tubing and welded it in a "T" to the end of the 90 degree curve. You can see something extra on the right hinge. It makes a convenient way to store the bolts for securing the grinder to the mount attachment. The narrow slot between the two extra pieces in the center is positioned so the cut off wheel fits into it. That worked pretty well until I used some water to cool steel I was cutting. Originally I used some scrap chip board shelving for a base. I will explain that in the next two steps. Step 4: Weld the hinges to the base Here you see the welds for attaching the hinges to the base. Welding a frame of steel sounds easy. but it takes some special care to have a frame that lays flat when finished. Step 3: Weld a base I had some 3/4 inch square tubing I used to make a base for the cut off saw.

The nuts distorted a little during welding and I tapped them after welding. you can see the 1/4 x 20 nuts I welded to the main arm to receive the bolts that hold the grinder firmly against the arm. Step 6: Depth of cut adjustment--part 2 I drilled a 5/16 inch hole into the right hinge under the lateral piece of 1 inch square tubing. I wanted a limiting stop to regulate the depth of cut as the cutting wheel wears. I found this a helpful addition to the cut off saw. Then I inserted a 1/4 inch bolt with a locking nut on it. http://www. It is long enough to reach down to the tapped mounting holes in the grinder head. This allows me to change the limit stop on the saw as the blade wears.instructables.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/ . I drilled a hole in a square of thicker steel and tapped it for 1/4 inch x 20 thds. Step 7: Vertical support for the grinder I welded a piece of square tubing in vertical position to support and attach the grinder. Although it comes later.Step 5: Depth of cut adjustment--part 1 Here you see a partially used cutting wheel on the grinder and a new wheel. I welded the square of steel over the hole in the hinge.

I used 1/8 x 3/4 inch strap iron across the ends of the horizontal piece. Then I clamped that piece of strap iron to one end of the horizontal piece. I clamped it and tack welded it. I had to grind a triangular notch into it to fit around part of the grinder case. Then I finished my welds and cut off any extra strap iron from the ends closest to the camera. It is important that you make sure you keep the grinder aligned at each step so that the cutting wheel will be at 90 degrees to the base and also 90 degrees to the fence you use. There is the possibility of compensating for any error as you go. This allowed minute adjustments before tack welding.) I clamped the grinder in place and lined it up as precisely as possible. I welded a nut to the end of each piece. (The visible welded nut is painted yellow. I used 1/4 inch bolts and made thumb adjustment levers for them from 3/16 inch rod bent at an angle and welded to the bolt heads.Step 8: Cut the vertical and add a horizontal piece Cut the vertical piece from the last step to length and add a horizontal piece at the same height as the tapped holes in the grinder head. Step 7 shows the attachment of the nuts to the main arm.instructables. then I drilled them out so the mounting bolts can slip through them with ease. Step 9: Upper mount for the grinder I used a piece of 1/8 x 3/4 inch strap iron to hold the upper portion of the grinder against the main arm. http://www. I screwed one bolt into the grinder head with its strap iron and welded nut in place. Then I attached the other piece of strap iron and checked to make certain the cutting wheel was still in alignment. Before putting them in place or cutting them to exact length. You want your cuts to be square when you use the saw.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/ .

Step 10: The fence The saw needs a fence to hold work pieces against the rotation of the cutting wheel and to assure accuracy. I welded two tabs to it so I can clamp it in place with "C" clamps. I may yet modify the way I mount the saw for use. http://www. This has been a valuable addition to my workshop. I used a piece of angle iron from an old bed frame.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/ . I made two small nicks in the base frame with a hacksaw so I can quickly align the fence again if I remove it to cut something without the fence. Currently I use a couple of larger "C" clamps to mount it on the top of a saw horse. To use I simply squeeze the grinder's switch with my right hand while lowering the saw into the steel I am cutting. Then I would remove the grinder when I needed to grind or cut something freehand. The price I pay for that is the shower of sparks shoots back at me rather than toward the front of the cut off saw. I made a sheet metal deflector I clamp to the cut off saw's frame. I ruined a good polyester sweatshirt. Eventually I got some Christmas money I used to buy a second angle head grinder so that I can leave this grinder in the cut off saw attachment. I prefer to look at the work from the left of the cutting wheel and to use my right hand to operate the saw. Step 11: The shower of sparks Perhaps I should have mounted the grinder rotated 180 degrees clockwise so the cutting wheel would be on the right side of the grinder rather than on the left side of the grinder. It works very well. Initially I would mount the grinder when I needed to make a precise cut.instructables. But. Before I made it.

Related Instructables Too Much Flex in a Circular Saw Base by Phil B Sword Making by Stock Removal by Deathatsix 600W Electric Trike by smegger A Precise Table Saw from an Electric Hand Saw by Phil B How to weld a barbecue. Phil B says: Feb 10. Just the thing for those smaller cut-off projects. The second grinder I bought has angled holes in the head. 8:37 PM REPLY you should use a cable tie to hold down the grinders switch and make a a foot operated momeruntry switch and plug the grinder into that Phil B says: Aug 8. but it would present a couple extra little challenges. 2009. 7:19 AM REPLY If I used this tool more regularly I would probably do that.instructables.com/id/Cut-Off-Saw-from-an-Angle-Head-Grinder/ Feb 9. The tapped holes on this grinder are 180 degrees opposite one another. rimar2000 says: Feb 10. Lftndbt says: "Angle Head Grinder" Got to love it! . Sometimes I cut something too big for a single cut. Thanks.) Preparing for Zombie wars anyone? http://www. 9:08 PM REPLY . 2009. by Kiteman Build a Really Good TriSquare by Phil B Comments 6 comments Add Comment harvey639 says: Aug 7. 2009. but it is easy to stop and roll a piece of pie for another cut until I get all of the way through the piece. 2009. I find most of what I do are fairly small projects. It would still be possible to make one of these for angled holes. 200 amp) welder. 6:59 AM REPLY Even though I have a big (230 volt. A small cut off saw works fine for cutting 3/4 inch square tubing or 1/8 inch strap iron. 2009. 2009. prestux says: Feb 10. 5:35 AM REPLY Excellent idea! I just happen to have a extra angle head grinder that could be converted into one of these. 4:30 PM REPLY Very useful tool.