DIY Bench Grinder to Belt Sander Conversion

We show you how we turned our bench grinder into a 2x42 belt sander. We modeled everything on Fusion 360 which allowed us to print the sketches to scale so we can use them as templates for easy cutting. You can download the templates by clicking the link to our website below:
imeemade.com/b...
The materials we used for the modification are shown below. (Please note that these are affiliate links and we do get a small commission if you purchase any of these and it really helps us to make more projects for our channel, so thank you in advance!)
2 x 42 inch Sanding Belt Assortment: amzn.to/3d6KKLG
2 x 72 inch pulley set: amzn.to/2WhLyGY
5/8 - ½ Reducing bushing: amzn.to/3bVLgfu
Extension spring: amzn.to/2zMqhxf
3/16” steel plate: amzn.to/3FZ07pK
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[@IMEEMADE]

Despite the unexpected turn of events when making this belt sander, we love how it turned out! We're excited to put this thing to use 😁

[@a.b.k1983]

This has to be the best DIY belt grinder video I’ve come across AND the fact that you shared the plans and links. I liked and subscribed!

[@IMEEMADE]

Thank you very much!

[@laural5703]

Time to sand all the things!! My favorite part was the makeshift hinge! Been wanting to try that for so long!

[@IMEEMADE]

Yeah! We're so darn cool

[@goranmarinic2923]

I like you put it on the left side of the motor, well done!

[@IMEEMADE]

Thank you!

[@РоманГречко-и3ц]

Thank you very much for your full instructions from Kazakhstan. A very competent project for home conditions.

[@minor805]

Well done. Great video and much appreciated on the prints. Definitely will have to check them out if I end up going this route.

[@IMEEMADE]

Thank you very much!

[@redmer83]

Nice and simple build, first one I see that is not overly complicated. And nice to show a 1HP grinder is needed :)

[@IMEEMADE]

Thank you so much for checking it out! Glad you found it helpful 😊

[@gsheneikaty5805]

Hi

[@jumpnjack8686]

Best DIY build for home enthusiasts. Mostly cutting, cleaning and fitting with minimal welding. I can do this! Thank you, thank you, thank you. Great design.

[@IMEEMADE]

Thank you very much! It was a very fun and low-stress project. Hope you enjoy the build also :)

[@fonhollohan2908]

Love that idea, with the bolt and nuts to weld and make a hinge that alone was worth the watch.

[@IMEEMADE]

Thank you so much! We're glad the hinge worked out as well as it did lol

[@dmitriytepaev5481]

big TNX from Krasnoyarsk 4 templates

[@OZseasnake]

Great video and well made, thank you for the template

[@marty4645]

IMEE, thank you for your awesome video and especially the plans, greatly appreciate it. God bless.

[@IMEEMADE]

Thank you for watching and hope you have fun with the build!

[@coils1945]

A little late for a comment but thank you very much for making this video. Also thank you for the template and parts list! This looks really good!

[@IMEEMADE]

Thank you so much!

[@ridermak4111]

Fantastic design and execution ! I’m late to this party and maybe it’s already been covered, but a very useful feature would be variable speed….or for less $$, a half speed grinder at 1750 rpm. The half speed would suck though when rapid removal of material with a coarse grit belt is needed. The variable speed ($$) is worth it if finer grit belts are doing careful shaping and finishing. In either case heat is the enemy. Keep a full bucket of water next to the grinder for dipping if the workpiece starts turning blue. The goal is to dip before the blue shows up though. Again, what a great project !! It certainly does NOT look homemade. 🤜🤛

[@IMEEMADE]

Great idea, that would be a neat addition.

[@albertosalamanca9154]

Muchas gracias Dios derrame muchas bendiciones en usted por tomarse su tiempo para enseñarnos y compartir los pdf Dios le de mucha salud gracias un abrazo desde Colombia Bogota

[@IMEEMADE]

muchas gracias!! 😁

[@cmega3777]

Great build. if i may suggest....use cutting oil. It's messy but it makes for better drilling and longer tool life.

[@IMEEMADE]

Thanks for the tip!

[@JTheoryScience]

when you dont have a CNC machine... its time to bring out the arts & crafts :P

[@Tony71570]

Best diy belt sander I've seen. Great job!!

[@IMEEMADE]

Thank you so much!!!

[@joe4282]

Awesome video. I wonder if you could retrofit this to be a band saw.

[@anneg4361]

thanks for the plans now get time to build thank you again

[@IMEEMADE]

Thank you for watching!

[@stephengriffith1605]

Great job you make it look so easy. I think I might give this a try

[@IMEEMADE]

Thanks!! It honestly isn't too bad! Just a lot of cutting then it's smooth sailing after that 😃

[@DesignCraftWorkshop]

awesome video guys. Great explanation the entire time!

[@IMEEMADE]

Thank you so much!

[@charlottechurch6327]

Thank you,it made things easy

[@IMEEMADE]

Glad to hear. Thanks for watching!

[@_lumpy8859]

I see a 5" drive wheel set, half the money of the recommended set. How much impact do you think it would have? Thanks

[@DNSforge]

Question. Is the flat plate welded to the smaller piece? The work plate I mean.

[@vincentcocuzza8679]

Hey love the video and I used y’all’s template and built my own and it’s amazing the only thing is what spring did y’all use? I followed the link y’all included for the extension spring but I’m not sure it’s the correct one so if you can please let me know what size it is. Thank you so much for the templates!

[@IMEEMADE]

We double checked the link and it's the same one we ended up using at the end. The video does show a different kind where we doubled up and it worked ok but would bind sometimes so we found the one linked which works better

[@vincentcocuzza8679]

Awesome thank you so much and yes I ordered wrong one on accident so I ended up getting the correct one and works great!! Thanks again!!!

[@IMEEMADE]

@@vincentcocuzza8679 glad to hear!! Thank so much for watching!

[@garagemonkeysan]

Nice video and editing. The grinder looks great. I see a forge in your future. : ) Mahalo for sharing! : )

[@IMEEMADE]

Thank you! Haha not sure we're responsible enough to have a forge in the shop just yet

[@fcolon1976]

What type of angle grinder cutting disc did you use please?

[@TheMadawg67]

Templates were free and links for everything subbed thank you

[@IMEEMADE]

Thank you!! Hope you have a good time building it!

[@georgefrattarelli7978]

The 72” link has 4 wheels, which obviously doesn’t line up with your 46” design. Did you have a vision or template extending it to the 72” or should I get creative with the 4th wheel extension to 72”

[@IMEEMADE]

Just use 3 out of the 4 wheels. Or you can add the 4th wheel into the mix, the world is your oyster!

[@residentmaker]

"...and then proceeded to burn myself." You get a sub just for that. Great build.

[@IMEEMADE]

Thank you so much!

[@stevenlangerud6644]

Made me laugh at that. Been there and done that many times.

[@angelogiannetti]

thanks a lot for free template

[@IMEEMADE]

Our pleasure!

[@doggylv]

This is exactly what I have been wanting to make, great job BUT the plans come outs as 15 3/4 and the steel is 12 x 12, please advice, thanks...😳

[@IMEEMADE]

Oh no the Amazon link should route to a 24x24 sheet. Thank you for letting us know, we'll switch the link to the appropriate size!!

[@doggylv]

@@IMEEMADE thank u for responding, was confused about what was what!

[@carlossanchez8534]

I see people building square belt sanders..is there an advantage from your triangle shape over the square shape ones out there?

[@IMEEMADE]

People building square sanders have a more powerful motor. My setup uses fewer wheels for low HP motors found on these bench grinders

[@IronManRestoration]

You done a great job. Can you make one for me please?

[@denniscrimboli3878]

Is it possible to make me one contact me area code 239-223-4838

[@IMEEMADE]

Feel free to reach out to us at [e-mail] we'd love to work with you guys!

[@IronManRestoration]

@@IMEEMADE thank you

[@mp180170]

I hit the subscribe button because you asked so nicely 😃 love the video O & I likes as well happy days 👌🏼

[@IMEEMADE]

Thank you very much!!

[@КурмашБуралхинов-б4н]

Hello, very good grinder! Where I can find this paper metres?

[@sebastianpietrzyk9138]

Where did you get those pulleys from?

[@edwardwhite6353]

Nice build! I'd like the plans also please

[@IMEEMADE]

Thanks the link is in the description!

[@donparr5359]

Hello, I’m getting into nice making and other projects I need a grinder just like you made. Any chance you can send me the templates and your rollers which ones to use where you got them part numbers. Thank you

[@IMEEMADE]

Everything you need is in the description! Have fun!

[@tariqmahmood8168]

Hello please could i have a copy of the instructions on how to build it many thanks

[@IMEEMADE]

Hi Tariq! We have the write up and the link to the template on our blog. imeemade.com/blog/diybeltsander Have fun making!

[@TeeJay1370]

Love this video thanks for making it, one question for you where did you find the pullies that you used. Thanks in advance.

[@IMEEMADE]

Thank you! We have a link in the description to the set we used :)

[@TeeJay1370]

Thanks for the reply didn't even see the first time, but thanks again, keep those videos coming, there really helpful.

[@IMEEMADE]

Thank you very much!

[@integratedalchemist]

How many volts is the 1HP grinder? I only have access to 120

[@jamesali7218]

What did you draw this up in ? And could I get link or file for it ? Would like to make a slight adjustment to take a 2x48 belt

[@IMEEMADE]

we used Fusion 360 and have a template available for download on our website! imeemade.com/blog/diybeltsander

[@DjZyklon]

You put the tracking wheel stationary at the back and put the pivot on a normal idler. Was there any reason for that? Have you noticed any rattle when you try tracking the belt?

[@IMEEMADE]

To be honest, I didn't have a particular reason for doing it that way. However, there's no issues at all tracking the belt.

[@bahadursingh8991]

Fantastic🤘😝🤘 video❤

[@moosehunter76]

I recently came across this video and had to make one myself. Got everything from your links except the steel which I had, and I just got everything assembled and put on a .9 HP grinder. There seems to be too much tension with my belt installed. Is it possible I need a slightly weaker spring than the one in the link?

[@IMEEMADE]

Hmmm it could be possible that the spring we used is too stiff for your grinder. You can try one with a lower spring rate and let us know!

[@story-yj6sg]

ให้รายละเอียดครบดีมากสำหรับคนที่ไม่มีความรู้ ว่าใช้อะไรบ้าง ติดตามแล้วครับผมมาตากประเทศไทย

[@IMEEMADE]

Thanks for watching!

[@jajos22]

Hey great video.

[@IMEEMADE]

Thank you!

[@tukangotakatik9914]

Thanks

[@IMEEMADE]

Thanks!

[@BenNawrath]

Quick question. Ballpark how tall is the unit once all is said and done? I have an 8” grinder I’d love to do this to, left side and everything. But I have potential clearance issues to my cabinets.

[@IMEEMADE]

The whole setup is about 16" tall overall. 14" from the center point of the shaft to the highest point

[@BenNawrath]

IMEE MADE thanks! Time to bust out the trusty Stanley tape...

[@christopherhutton2035]

DO you have the fusion files we can download? I have a small plasma table and would like to cut the parts out a file would save me a lot of time. Thanks man its an awesome looking grinder/sander

[@IMEEMADE]

Thank you so much! Unfortunately I don't have the fusion files anymore, but the DXF is available on our website! imeemade.com/blog/diybeltsander

[@renanrojas3763]

Gracias por la ayuda y la atención

[@chancetolbert4852]

Do you think it would work with 1/2 hp grinder?

[@IMEEMADE]

I would say with this set up, 1/2hp would work, but would probably have a little trouble grinding something heavy duty

[@angelbautista7785]

What kind of welder are you using?

[@IMEEMADE]

Using harbor freights Vulcan protig 200

[@GregGarza-k5v]

Can u send me the templates as I can't find them on the site?

[@chrismacias1149]

Where can I get the wheels u used on this build? Great job by the way.

[@IMEEMADE]

Thank you! Everything we used is linked in the description 😁

[@uni3831]

how big was the steel plate you used to make this? if you remember,

[@IMEEMADE]

I believe it was about a 12" x 24" piece of steel we used. You can download the template to get an idea of the actual size. Here is the link: imeemade.com/blog/diybeltsander :)

[@patrickbeaudreau]

Great build do you mind sending me the plans?

[@IMEEMADE]

The link to the plans are in the description

[@khairilabdmajid9005]

Where can I get the blue print of this machine

[@IMEEMADE]

We have a full scale PDF of all the structural pieces. Feel free to email us if you need more details

[@MrPauls-vr4mj]

One critical error. The downloaded template doesn't fit a 12"x12" piece of steel. At least not how I downloaded it.🤔

[@nucuradu]

Hi How can I get the drawings for the parts. Thank you!

[@IMEEMADE]

Our write up has a link to the file: imeemade.com/blog/diybeltsander

[@Coalblack79k10]

Make the aluminum wheels??

[@adamrector4700]

How much are the prints

[@IMEEMADE]

They're free on our website. The link is in the description! 😁

[@DNSforge]

Are you able to give the dimensions from hole to hole and things of that sort?

[@IMEEMADE]

We have a template on our website you can download for free!

[@DNSforge]

@@IMEEMADE I know that, but it doesn’t have any measurements on it. I am going to have it plasma cut out but I don’t know how y’all or wide you made it do you have those dimensions?

[@stevenlangerud6644]

@@DNSforge I liked the fact that the initial mistake in the mounting drill holes was shown in this video. If you are planning on building or designing your setup using a bench grinder like the OP, then you can get the measurements you seek as it was done at around then 5:22 mark in the video. I would venture to say that would be advisable because not all bench grinders are made the same. At the 7:47 mark this is confirmed. :) Good Luck!

[@carlossanchez8534]

Hi.. Can you tell me how much this will cost me?

[@IMEEMADE]

We have links to all the material we used in the description. Biggest expense will be the grinder so it's tough to say how much it'll be

[@carlossanchez8534]

@@IMEEMADE I have the grinder already.

[@FireCrowsWorkshop]

Really cool and well executed but am I the only one seeing an issue with all this extra weight with added rotational tension of the belt being held by 3 tiny screws attached to the side of the grinder? Personally I’d use them as locating screws and extended the bracket/body of belt grinder to underneath of the grinder. If it fails in its current shape and form, it’ll be quite spectacular

[@IMEEMADE]

Thanks for your input! Overall, the rotational moment about the three screws holding on the plate to the body is pretty negligible. Also the static loading of the additional components aren't enough to degrade the performance of the screws. I definitely didn't run an FEA, but from a "back of the napkin" calculation, there isn't enough torque to shear one of the mounting screws while in use. I don't quite consider the application to be cyclically loaded for the screws to fail from fatigue either. Your suggestion is totally valid and others should consider additional safety mechanisms if they wish to. So far, I've been using this setup for 2 years pretty consistently without issue!

[@sanjuparmar8916]

How i order ??

[@carlosjasso356]

Por favor díganme como obtener las plantillas, se lo voy a agradecer mucho

[@Brendan9300]

This would be great if in metric

[@CerradoGoias]

Muito bom

[@IMEEMADE]

Thank you!

[@apatbond2864]

Cant download the template..link crushed after key in email

[@IMEEMADE]

Sorry about that! Sometimes having popups blocked will prevent the link from loading. Please send us an email to [e-mail] and we'll be happy to send you the file!

[@jairmartmalquisto2383]

How much sir?

[@michellelose2361]

First one showed missing parts. Second one was complete. It's a working bench grinder kzbin.infoUgkxxC8HPnl24fu0XhMU_nbmWNEUoK1RMHXk . One thing I like alot is that it's surprisingly quiet. I don't feel like I'm sacrificing any rpms or power for the quietness either. All in all it's a very nice machine. No vibration whatsoever.

[@vd1261]

Hello. How many watts does the motor of your sander have? Thank you

[@monstreniaiseux]

Anyone know if the Dewalt grinder dw756 is strong enough for this?

[@monstreniaiseux]

And where can we find the 3 aluminium bushing (the thing that the belt slide on)and what’s the size if them?

[@IMEEMADE]

All the items we used in are linked in the description including the wheels. Also this setup is best used with grinder motors with at least 3/4 horsepower. Thank you!

[@izbiz671]

Nice build though however, there's not enough horsepower. I tried to build one with my Dewalt 8", 3/4HP, I could slow down the drive wheel with my hand.

[@IMEEMADE]

Agreed! At 7:00 I addressed this exact issue. The Craftsman grinder was too weak, so we swapped everything over to a 1hp grinder!

[@archangel20031]

A few things they failed to see. Not enough Real estate for 2x72 belt grinder? Not true as the whole reason for it being 72" long is so that the belt can cool off before hitting the hot metal again, so it can go anywhere to cool, even up, or down, just anywhere out of the way, so they could have easily made that grinder frame longer to hold a 72" long belt! And cost is another non-issue as if you are building it and cutting metal parts, making them a little longer would not cost much more if anything at all when using scrap. The only expense I had on my 2x72 belt grinder was the 3 plastic 2" wide idle wheels @ $17, everything else was scrap including the treadmill motor.

[@IMEEMADE]

Great job. But what you missed is that we said BUYING a PROPER 2x72 isn't ideal for us because of the real estate and cost. A proper 2x72 does, in fact, have a much larger foot print and much more expensive than a DIY solution... Thanks for watching the video though!

[@hamedali5819]

جيد جدا

[@fabianpozo7107]

THE PLANES

[@IMEEMADE]

Planes?

[@alejandrom2144]

@@IMEEMADE los planos donde los consigo

[@IMEEMADE]

@@alejandrom2144 The plans are available to download here imeemade.com/blog/diybeltsander

[@jamesmcvey7472]

no plans to DL

[@IMEEMADE]

The template is available for download on our website: imeemade.com/blog/diybeltsander

[@hwfranjr]

If ya just happen to have a grinder it’s ok,if not better to just buy S sander unit,lol

[@IMEEMADE]

Absolutely. This isn't a "cheaper" solution by any means. It's more of an exercise of repurposing something you already have. Thanks for watching!

[@иванкривобочек]

Нихуя не понял, но очень интересно👍

[@IMEEMADE]

Thank you!

[@colinmartineau4737]

I wouldn't let a child use a grinder, almost any other tool in the shop sure but not a grinder. Especially not without a face mask. Last thing your daughter needs is a huge scar on her face.

[@mikebromell3072]

Drop the annoying music next time

[@IMEEMADE]

there's a mute button you're welcome to utilize

[@ЮргисПакитурис]

С жиру бесится товарищ...

[@lonewolf9390]

How many of the 12x12 3/16" thick steel plates do you need for this project?

[@IMEEMADE]

Here’s a link to the proper plate. You need one 12x24” sheet. Sorry for the confusion! amzn.to/3FZ07pK

[@lonewolf9390]

@@IMEEMADE Thanks!