Need a sturdy angle gearbox to handle power transmission for your next big project? Why not harvest a rear axle from a car and make one yourself?
When you think about it, the axle of a rear-wheel drive vehicle is really just a couple of 90° gearboxes linked together internally, and a pretty sturdy assembly that’s readily available for free or on the cheap. [Donn DIY]’s need for a gearbox to run a mower lead him to a boneyard for the raw material. The video below shows some truly impressive work with that indispensable tool of hardware hackers, the angle grinder. Not only does he amputate one of the half axles with it, he actually creates almost perfect splines on the remaining shortened shaft. Such work is usually done on a milling machine with a dividing head and an end mill, but [DonnDIY]’s junkyard approach worked great. Just goes to show how much you can accomplish with what you’ve got when you have no choice.
We’re surprised to not see any of [DonnDIY]’s projects featured here before, as he seems to have quite a body of hacks built up. We hope to feature some more of his stuff soon, but in the meantime, you can always check out some of the perils and pitfalls of automotive differentials.
Continue reading “Hacked Car Axle Yields Custom 90° Gearbox”
Faced with a project requiring a lot of sanding, [George] had two options. Suck it up and buy a belt sander — or re-purpose a tool he already had to do the same job. He chose the latter, and turned an angle grinder into a belt sander.
Part of a series called Make It Extreme on YouTube, [George] built the entire project from scratch using raw materials. Using a lathe he created the aluminum rolling dowels the sanding belt will sit on. He pressed bearings into them, and then welded up a frame using scrap steel to hold them apart. He’s even added a spring-powered tension device to ensure the belt stays on.
As for mounting the angle grinder in place, it couldn’t be easier. It slides in between two metal guides, and attaches using the threaded hole for the angle grinder’s handle.
Continue reading “Turning an Angle Grinder into a Belt Sander”
When it comes to picking out high-end fixtures and appointments for your bathroom remodel, there are tons of choices out there these days. Sure, that double-slipper tub or $2500 stainless steel toilet can make a statement, and even the local Big Box Home Store has some pretty unique stuff. But for a one of a kind sink, follow [The Samurai Carpenter]’s lead and carve a sink out of a boulder.
Starting with a stone he found off the porch of his house, [Samurai Carpenter] was able to rough out the shape of the basin with a diamond-bladed cutoff saw. A few plunge cuts within a hand-sketched outline gave him the room needed to hog out most of the material with a cold chisel and hammer. A diamond wheel on an angle grinder, along with a chisel bit on an impact drill, got him down to the final smooth finish. After the break there’s a video showing the final installation, including drilling out the drain hole and mounting the sink to the vanity, which is a beautiful rough-cut slab of what appears to be locally sourced wood. The whole installation looks fantastic and appears to function well; our only quibble is there’s no overflow in the basin, but it’s hard to see how he could have provided one without significantly complicating the project and potentially ruining the aesthetic.
Although they may not fit in with the natural vibe of his remodel, either this or this tricked out mirror could complete a high-end bathroom remodel.
Continue reading “Natural Materials For Nature’s Call”
Surface Grinders are machines that can make a surface of a part very flat, very smooth and very parallel to the face of the part that is mounted to the machine. Surface grinders usually have a spinning grinding wheel suspended over a moving bed. The bed moves the part back and forth under the grinding wheel removing an extremely small amount of material at a time, sometimes down to just a ten-thousandth of an inch (o.0001″) in order to make a precision part.
[Daniel] is a tool guy and wanted a Surface Grinder. He didn’t need a super-accurate commercial grinder so he decided to make one himself. It’s a doozy of a project and is made up of quite a few other tools. [Daniel] already had a mini CNC mill and decided this would be a good platform to begin with. The mill was rigid and already had automated X and Y axes, after all. For the grinder motor, nothing made more economical sense than to use a regular angle grinder, but there were two significant problems. First, no company made wide grinding wheels for an angle grinder. [Daniel] had to modify his spindle to accept an off-the-shelf surface grinding wheel. The second problem is that the new grinding wheel had a max RPM rating of 4400. The angle grinder can reach 10,600 RPM. In order to slow down the angle grinder, a speed control was taken out of an old variable-speed router and integrated with the angle grinder. Problem solved. A mount was then made to attached the angle grinder to the Z axis of the mill.
A magnetic chuck mounted to the mills bed is used to hold down metal work pieces. There is a lever on the chuck that when moved in one direction it creates a magnetic field to hold a ferrous piece of metal firmly to the chuck during machining. When the lever is moved in the other direction, the part is released and can be removed from the Surface Grinder.
To use his new Surface Grinder, [Daniel] creates a CNC g-code file to move his work piece back and forth underneath the grinding wheel. Being able to control the depth of cut and feed rates with his CNC machine removes human error from the grinding process and leaves a consistent finish on the part. Check out the video after the break.
Continue reading “DIY Surface Grinder for making Precision Parts at Home”
[Saeid Momtahan] made a couple of attachments that let him use his angle grinder as a bench grinder. It may be better to refer to it as a bench motor, as he uses both a grinding wheel and a wire brush while showing off his project.
The attachments come in two parts. The first is a piece of square tube that runs parallel to the body of the grinder on the side opposite the handle. This doubles as a larger gripping area when using it as an angle grinder, as well as giving him something to clamp in his bench vise. The second attachment serves as a rest for the work piece. Above you can see him brushing some rusty stock clean with the wire attachment.
It’s nice to have the option of doubling up a tool’s tasks rather than buying yet another item that may not get used all that much. We also love the idea of building your own tools. If you don’t have a welding rig to fabricate these add-ons here’s a li-ion battery based system to get you thinking.
Continue reading “Using an angle grinder as a bench grinder”