MW- BELT GRINDER

V2.0
Build Instruction
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© Mario Wurzinger
Content

1. Regulation........................................................................................................................................ 3
2. General Information ........................................................................................................................ 3
Part Overview: ..................................................................................................................................... 5
Dimensions of the Motor .................................................................................................................... 7
3. What do you get? ............................................................................................................................ 8
3.1 CAD Data: ................................................................................................................................ 8
3.2 BOM:........................................................................................................................................ 8
3.3 DXF Files: ................................................................................................................................. 8
3.4 Drawing: .................................................................................................................................. 8
3.5 Additional Information’s: ........................................................................................................ 8
4. Preparing the parts .......................................................................................................................... 9
1. Stand............................................................................................................................................ 9
2. Rotation- Plate:............................................................................................................................ 9
3. Tension Arm .............................................................................................................................. 10
4. C- Plate ...................................................................................................................................... 10
5. Fixing Rail ................................................................................................................................... 10
6. Grinding Plate ............................................................................................................................ 11
7. Tension Plate ............................................................................................................................. 11
8. Precision Rod ............................................................................................................................. 11
9. Main Plate ................................................................................................................................. 12
10. Main Plate Engine .................................................................................................................. 12
5. How to build the Grinder? ............................................................................................................. 13
5.1 The Base: ............................................................................................................................... 13
5.2 Up to Main Plate.................................................................................................................... 15
5.3 The Tensioner ........................................................................................................................ 17
5.4 Engine Plate ........................................................................................................................... 17
5.5 Tensioning System ................................................................................................................. 20
5.6 Grinding Area......................................................................................................................... 21
5.7 Working Table ....................................................................................................................... 24
5.8 The Machine .......................................................................................................................... 25
5.9 Finalization ............................................................................................................................ 26

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 1. Regulation
All information’s and data in this package are for free and can be used to build
your own DYI Belt Grinder.
This package is not intended to be sold. The rights to this machine are reserved to
the designer.

2. General Information
I did the design of this grinder with focus on durability and functionality. Therefor, the design
is very stable and heavy. The final weight might be up to more than 80kg (depending on the
motor).

• The units in this package are in mm → 1inch = 25,4mm

Main Dimensions:

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Part Overview:
• 29 total laser parts
o 13 laser parts with 10mm material Thickness
o 16 laser Parts with 15mm material Thickness
• 3HP (3Phase) Motor - LINK I am using this motor

• 2,2KW VFD - LINK I am using this VFD. Capability to handle 2,2KW

• 2x 30x30 Precision Rod - LINK (500mm Length). Currently I got 4 of them to get also a
contact wheel and mall wheels to change the system.

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 • 16x M8x60 Screw
• 16x M8 Nut
• 12x M8x20 Screw
• 4x M8x45 Screw
• 3x M10x35 Screw
• 1x M10x60 Screw
• 1x M10 Nut
• 2x M10x20 Screw
• 2x M10x30 Countersunk Screw
• 3X M12x60 Screw (depending on the wheels)
• 4x M8 Clamping Lever – LINK (length of the thread should be about 25mm)
• 4x M10 Clamping Leaver - LINK (length of the thread should be between 30mm and
max. 40mm)
• 2x M8 Ball Joint
• 1x M8 Tightening Screw
• 2x M8 Ball Stud
• Set of Grinding Wheels - LINK I am using this wheels with 6” on the Main Wheel to get
also the preferred speed on the belt.

For the Screws I am using hexagon socket screw with thread from beginning to the end of the
screw.

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Dimensions of the Motor

Important here is the hole pattern which got implemented into my 3D Design.

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 3. What do you get?

3.1 CAD Data:

I am using Catia. Most of you will have a different 3D System, therefor I am creating
STEP files which can be used normally with all CAD Systems.

3.2 BOM:
The BOM (Bill of Material) is an Excel file where you can see all the necessary parts to
build the grinder.

BOM
# Partnumber Partname Filetype Drawing DXF File Quantity Thickness [mm] Material Remark
1 BG_1001 Belt-Grinder CAT-Product NO NO - - Master Product - contains the complete grinder files
2 BG_1002 Skelett_Model CAT-Product NO NO - - Contains the main sketches for the parts
3 BG_1003 Stand-Compl CAT-Product NO NO - - Base for the grinder
4 BG_1003.1 Base_Plate CAT-Part NO YES 1 10 S235 Laser cutting Part
5 BG_1003.2 Stand CAT-Part NO YES 2 10 S235 Laser cutting Part
6 BG_1003.3 Stand-Reinf CAT-Part NO YES 2 10 S235 Laser cutting Part
7 BG_1004 Working-Table CAT-Product NO NO - -
8 BG_1004.1 Work-Plate CAT-Part NO YES 1 15 S235 Laser cutting Part
9 BG_1004.2 Precision-Rod CAT-Part YES NO 2 30x30 S235 Buy part
10 BG_1004.3 Angle-Brkt CAT-Part NO YES 1 15 S235 Laser cutting Part
11 BG_1004.4 Fixing-Rail CAT-Part YES YES 1 15 S235 Laser cutting Part
12 BG_1005 Grinding-Area CAT-Product NO NO - -
13 BG_1005.1 C-Plate CAT-Part NO YES 1 10 S235 Laser cutting Part
14 BG_1005.2 Grinding-Plate CAT-Part NO YES 1 10 S235 Laser cutting Part
15 BG_1005.3 Fixatzion-Brkt_1 CAT-Part NO YES 2 10 S235 Laser cutting Part
16 BG_1005.4 Fixatzion-Brkt_2 CAT-Part NO YES 2 10 S235 Laser cutting Part
17 BG_1006 Main-Plate- Engine CAT-Part NO YES 1 10 S235 Laser cutting Part
18 BG_1007 Main-Plate CAT-Part NO YES 1 10 S235 Laser cutting Part
19 BG_1008 Distance-Plate CAT-Part NO YES 8 15 S235 Laser cutting Part
20 BG_1009 Tensioner CAT-Product NO NO - -
21 BG_1009.1 Tension-Arm CAT-Part NO YES 1 15 S235 Laser cutting Part
22 BG_1009.2 Tension-Plate CAT-Part YES YES 1 15 S235 Laser cutting Part
23 BG_1010 Rotation-Plate CAT-Part YES YES 2 15 S235 Laser cutting Part
24 BG_1011 Shim-Plate CAT-Part NO YES 1 15 S235 Laser cutting Part
25 BG_1012 Tension-Wheel CAT-Part NO NO 1 - Buy part
26 BG_1013 Wheel-small CAT-Part NO NO 2 - Buy part
27 MX3-90L_B34 Motor CAT-Product NO NO - - Buy part

3.3 DXF Files:

DXF is an 2 dimensional file which looks similar to a drawing. These files can be used
directly for a Laser or Plasma Cutter. I will separate the files for 10mm part thickness
and 15mm part thickness as well as one dxf file for each part – in case you need to get
spare parts.

3.4 Drawing:
For those parts where you need to do some additional work (additional holes and
thread) I will provide a drawing, in which you will find the position of the additional
holes.

3.5 Additional Information’s:

I also will provide the link to those parts, which I am using in my machine. This is just
for you as information, you don’t need to use them or buy those parts. Nothing is
sponsored.

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 4. Preparing the parts
90% of the grinder can be assembled with screws. Therefore, you need to get the thread into
the parts first.
Here you can see where a thread is needed. Most of the 3D Data have the right holes
implemented to get it already in the cutting process. Holes which can´t be implemented in the
cutting process needs to be implemented by you. Therefor you can find the exact position of
the hole in the drawing of the part.
Sometimes it will be necessary to clean these holes up due to quality issues based on the laser
process. Please make sure to use the right drill bit for these holes. Plasma cutting will lead you
to the same process.

1. Stand:

2. Rotation- Plate:

Exact position is in the drawing

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 3. Tension Arm

4. C- Plate

5. Fixing Rail

Exact position is in the drawing

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 6. Grinding Plate

7. Tension Plate

Exact position is in the drawing

8. Precision Rod

Exact position is in the drawing

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 9. Main Plate

10. Main Plate Engine

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 5. How to build the Grinder?

5.1 The Base:

For the Stand you will need a Weld machine.

Place the Stand into the holes. They will fit perfectly together.
For this part you will need a weld machine to fix them.

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Welding

Make sure that the parts are perpendicular to the base before welding them together.
8 times at the Stand Reinf and two times on the base plate. Don’t bring to much heat into
the base plate – it may warp if it is too much.

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 5.2 Up to Main Plate
What you need:

• The final welded Base complete

• 2x Rotation Plate
• 2x M10x35mm Screw
• 2x M10 Nut (would use self-locking Nuts)

• 1x M10 Clamping Lever LINK

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Next Step:

• Main Plate
• 4x M8x20mm Screw

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 5.3 The Tensioner
What you need:

• Tension Arm
• Tension Plate
• M8 thread rod (2x 25mm length) → is not shown in the 3D Data
• 2x Ball Joint - LINK
• M8 Tightening Screw - LINK

5.4 Engine Plate

After fixation of the Main Plate, you need to rotate it for 90°.

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What you need:

• 8x Distance plate
• Main Plate Engine
• 16x M8x60mm Screw
• 16x M8 Nut (would use self-locking Nuts)
• 2x M8x20mm Screw

Note: I added 0,1mm more material on both sides of the distance plate. Reason is, that the
surface quality of laser cutting is not always the best. With this added material you can clean
the surface without running into the problem, that the gap between will be too much.

Laser cutting Surface:

Dimension of this parts should be 15,2mm.

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 5.5 Tensioning System
What you need:

• Tensioning Assy
• Shim Plate
• M10x60mm Screw
• M10 Nut (would use self-locking Nuts)

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 5.6 Grinding Area
What you need:

• 1x Fixation Bracket 1
• 1x Fixation Bracket 2
• Grinding Plate
• C- Plate
• Precision Rod
• 2x M8x20mm Screw
• 2x M10x20mm Screw
• M10x40mm Screw
• 1x M10 Clamping Lever LINK
For the Fixation Bracket of the Grinding Plate, it is again necessary to do some welding. Here
it is important get those parts perpendicular.

Welding

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 5.7 Working Table
What you need

• Work Plate → you need to add the countersunk into the plate. NOTE: Long side of the
plate is left!
• Angle Bracket
• Precision Rod
• Fixing Rail
• 4x M8x45mm Screw
• 2x M10x30mm Countersunk Screw

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 3

5.8 The Machine

What you need

• 4x M8 Clamping Lever - LINK

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 5.9 Finalization
What you need

• 1x Grinder Wheelset - LINK I am using this one.

• 1x Gas Spring - LINK I currently use this 100N Gas spring. Before I tried a 250N Version,
but this is too much for the bearings. 100N is perfect.

• Motor - LINK

• 4x M8x20 Screws (Motor fixation)

• 2x M8 all Studs - LINK

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 Congratulation
Your Grinder is
finish

mariowurzinger1@gmail.com

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© Mario Wurzinger