Ultimate DIY Belt Grinder: TRACKING and TENSION Mechanisms - Part 2

Support Clough42 on Patreon: / clough42
A big thank-you to SendCutSend for sponsoring this project: bit.ly/3Vu5cw4
Belt Grinder Playlist: • 2x72 Belt Grinder
Today we're working on the belt grinder. This 2x72" belt grinder is my own design that I've been working on for about a year in my spare time. Today we're going to machine the tension arm pivot and the belt tracking assembly and put it together.
Tools used in this video:
*This site contains affiliate links for which I may be compensated
Bondhus Metric Hex Key Set (Amazon*): amzn.to/3eqZzwb
Bondhus SAE Hex Key Set (Amazon*): amzn.to/3h9bJLZ
YG-1 1/4" 120 degree spotting drill (Amazon*): amzn.to/3sVSLgv
Chicago Latrobe HSS Short Letter Drill Set (Amazon*): amzn.to/2PWx0dL
Chicago Latrobe HSS Short Number Drill Set (Amazon*): amzn.to/2Qgss0S
Chicago Latrobe HSS Short Fractional Drill Set (Amazon*): amzn.to/3mkmziD
Aventor 8" DPS IP54 Caliper (Amazon*): amzn.to/3KNwWaV
Starrett 3/8" Edge Finder (Amazon*): amzn.to/3CXja2N
HFS 1/4 x 6" Parallel Set (Amazon*): amzn.to/3kuPtQj
Astro Pneumatic Air Blower Nozzle (Amazon*): amzn.to/3oB5uE9
HFS 190-Piece (0.061-0.250") Gage Pin Set Minus (Amazon*): amzn.to/2DDSAf3
HFS 250-Piece (0.251-0.500) Gage Pin Set Minus (Amazon*): amzn.to/3cjEX5k
Scotch Brite Maroon Very Fine (eBay*): ebay.to/2FzIZco
Scotch Brite Gray Ultra Fine (eBay*): ebay.to/2QRJUXN
Shars 3-Point Internal Micrometers (Amazon*): amzn.to/3RqkNuc
Edge Technology Clamp Indicator Holder (Amazon*): amzn.to/3MImlhf
Shars .0005" dial test indicator (Amazon*): amzn.to/3lo3Stq
Goldenrod 10oz Pump Oiler (Amazon*): amzn.to/3OP0hlD
Noga Deburring Set (Amazon*): amzn.to/2xMfiPz
HHIP Mill Vise Stop (*Amazon): amzn.to/2Ki5VeP
Knipex Pliers Wrench 3-Piece Set (Amazon*): amzn.to/2ruzS8m
Raw Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License
creativecommons.org/licenses/b...
02:00 Turning the bushing rings
07:11 Drilling and countersinking the bushing rings
10:16 Drilling and tapping the tension arm
15:18 Milling the tracking yoke and plate
23:57 Assembling and installing the tension and tracking arm
29:49 Conclusion

[@g.tucker8682]

I appreciate the frank discussion of costs and build options. And the "tip" for faster dialing in on the mill with a DTI, I'm sure will come in handy in the future… heh, heh

[@TheDaumen]

One suggestion. On your tool arms that slide into the frame mill a shallow slot lengthwise where the clamping screws tighten against them. It doesn't need to be deep but those screws are going to mar the surface of the arms. If you mill a shallow slot those mars will be in the slot bottom and won't effect the sliding of the arms. Maybe your tolerances aren't so close that it would bother but on mine it would!

[@StefanGotteswinter]

Such a great looking grinder!

[@Clough42]

Thanks, Stefan! That's high praise.

[@joer7151]

Your work brings joy to so many. Thank you for building and filming (and editing, uploading, managing YT, etc.) for us to enjoy too!

[@randyshoquist7726]

Additional advice for form taps, the tap drill diameter is larger than for cutting taps because it's based on the pitch diameter of the thread rather than the minor diameter. It doesn't appear on common charts, you need a special one. And it's really critical. If the hole is even a tiny amount too small the tap can bind, because there's not enough space for the metal to displace into. I've never used them much, but sometimes they can be real problem solvers, and every HSM should know about them.

[@Clough42]

Yup. There are several places on the web where you can find drill size charts for form taps.

[@caseytailfly]

Ok so I need taper, plug, bottoming in straight flute, spiral fuse, spiral point, and form varieties, metric and imperial. I may need a moment here guys.

[@caseytailfly]

Oh and I didn’t even consider tool material or coating. I’m not addicted, I can stop anytime I want.

[@Tigglebitties]

More importantly, they need to be absolutely rigid. Usually more rigid than amateur home shop can manage, certainly never by hand. I gave up after breaking a couple. The runout on a drill press will snap them even if fixture is rock solid

[@Clough42]

@@Tigglebitties No, they're not that sensitive. You watched me power tap with them in my mill. I've done it by hand. Heck, I've even run them through steel with a cordless drill.

[@rsk4today]

I love it when a plan comes together.

[@MrGerhardFourie]

Awesome project James!! Your best yet, in my opinion. Thanks for sharing your experiences with us

[@markfletcher6511]

Being a fan of your channel, as well as Forged in Fire, I have grown to appreciate the value of a 2 x 72 belt grinder. Yours is beautiful to my eyes. I cannot wait to see first sparks. It looks like it will be very smooth. Thanks again for including in your videos a discussion of the design choices that go into each of your projects. The educational information is rivaled by the entertainment value of seeing your joy in seeing a project move forward so wonderfully.

[@EwokMatt]

Loving all your explanations as you work. Appreciate you being practical and not custom making every last part. Beautiful project.

[@mikemph7779]

I have tons of respect for you guys designing these things. It must be so satisfying. I’ve been a machinist for over 20 years but not designing anything. Thanks so much for sharing this !

[@MrGborel]

Super boulot! Tu fais rêver avec ton sens de la précision👏👏👏

[@mduvigneaud]

James, unlike that one commenter, I appreciate your honest and genuine talk about the parts from Send Cut Send. That and you repeatedly use them is *far* more compelling then if you were shilling hard for them.

[@billstrahan4791]

That looks lovely. Gorgeous work.

[@aaro_n]

Very excited for this build!!

[@DudleyToolwright]

There is a lot to admire. Beautiful project.

[@edwardlayton6835]

This is a very nice build ! Well done. Hope you document some more builds soon.

[@elmarqo_3448]

I'm really enjoying watching the work you do.

[@rogerbehrens4879]

Nice design and workmanship. Great job James…

[@KnightProLLC]

Thank you for all of your videos! Keep up the great work.

[@patpliley5535]

Looks great, love the colors and the logo.

[@michaellehmann280]

Great job James, and yes I'm excited!

[@stephenjohnson6841]

Really looking great James! Thanks again!

[@davidgeller6109]

So fun watching you work

[@Dudleymiddleton]

That is so nice one wouldn't want to use it and start wearing it out! Great build, James!

[@AmateurRedneckWorkshop]

That is certainly a nice looking belt grinder. I was a bit surprised at the cost. Thanks for the video keep in keeping on.

[@james.d.8044]

Beautiful job on the grinder love the channel 👏 ❤️ 😀

[@624Dudley]

Coming together nicely. 👍

[@xyzspec82]

I love Saturdays 😁

[@RRINTHESHOP]

Looking super James. I am sure it works great. 😊😊😊😊😊

[@kennethtencza9209]

Bada** James , keep the videos and projects coming.

[@GBWM_CNC]

Great design! I like the adjustment possibilities in the design. And the cleanliness of your work! That's a level which is hard to reach during mechanical work! :)

[@airgunningyup]

i like the A team reference 😄

[@madebyme757]

You’re a gem my friend

[@joell439]

👍👍😎👍👍 - Yep, even a very high quality DIY 2x72 grinder design is not cheap. Man, this is a very sharp and clean design.

[@amundsen575]

great build, I use Precision Needle-Tip Squeeze Bottles from mcmaster for cutting oils

[@ianbrown3733]

The best belt grinder build on YT!

[@frigzy3748]

I'm sorry, but the go-kart grinder from Fireball Tools is cooler just because it's bigger 😀

[@JohannSwart_JWS]

Couldn't help noticing, even with heavy tooling in the mill, how quickly it stops. That VFD (if you have one - I forgot) seems to do a great job. Such a nice build this one. Looking forward to part 3. Then of course, you'll be obliged to make a knife or 2. The challenge is to make a folder. Yes, I know you have a loyal BM AFCK (which I'm lusting after, but can't find).

[@Clough42]

It's a single-phase mill, and I'm stopping it using the brake handle.

[@v8packard]

The parts from SCS may not be perfect, but they are within tolerance and also freakin gorgeous. Thanks for the video.

[@mementomori4972]

Heart warming and wholesome,...brings tears to my eyes. Who needs cat videos, if you can watch something like this

[@orangetruckman]

The beeping from the DRO wasn’t that big of an issue for me at least 😬 I’ve got bigger issues in life than to concern myself with such trivial things. Another enjoyable video sir 👍🏻 loved the A-team reference 😆

[@douglasbattjes3991]

Great Great build, hope you can buy the frame from someone. One of the best builds I've seen. Where are the wheels from?👍👍👍👍👍👍

[@reaper060670]

Hey man. I would love to do some courses in how to use Milling machines the correct way. I wish I could afford one of those beasts u have behind u in the shot. I bought a loada gear to build my own DIY CNC Router but it hasn't quite worked to perfection atm. I'm new to all this CNC subject matter. Literally by a few months. I'm 51 yrs old this year and never heard of CNC machines until last year on YT. I bought a Laser Engraver just to see how these things work and I'm learning but it's the software I always struggle with. I'm about to begin building my own Welding table and Table saw. The parts are coming in thick and fast now and I cannot wait to begin next week.. I have collected some great ideas from others on here too. I love to pick and chose from others builds and attempt to put them into my own but time will tell if I have the skills to get it finished. The CNC ROUTER is close to running again. I think I messed up with the wiring of the electronics. It worked for a wee while then stopped. Now I have to break it down and rebuild from the beginning after learning some new things. I priced a belt sander like yours on VEVOR to the cost of 800 euros odd but it was nowhere near looking as good as yours bro. I doubt it had the nice parts yours had either. Your skills are brilliant pal. I love watching great craftsmen at work Yes u use machines but U also use ur hands too. I really enjoy these tyoes of videos and will be watching for more soon. Take it easy and salute from Dublin, IRE.

[@outsidescrewball]

Nice!!

[@MIR-jd8th]

Hi James, you did a great job. Perfect precision and elegant design. I am not a Machinist, but an Structural Engineer as wood working hobbyist. Anyway just a suggestion, do you think it is a good idea to install a try with Magnet with specific strength at the bottom to collect the ferro particles?

[@Clough42]

It might help. It would also be difficult to clean. :)

[@VoidedWarranty]

watching this caused 4 or 5 more tools I need to make go on the todo list

[@joat_mon]

Nice build! Thanks for sharing. That scar in the mini pallet looks familiar, I'm guessing that happened on the '704?

[@Clough42]

Yup. It's a classic case of TTS pullout.

[@NickNick2024]

This is like the Linus Tech Tips (LTT) screwdriver of grinders. I mean that in the most positive way. Very nice!

[@PorchPotatoMike]

The form tap is interesting, but since everything in machining is a compromise, what are the limitations or downsides? I saw another commenter mentioned the hole diameter is different and higher tolerance is required, but is there anything else?

[@chip-load]

They are not allowed on Aerospace work because the thread peak usually has a crack seen under inspection.

[@colinbrewhaha]

Nice

[@jaapweel1]

SendCutSend is pretty specific about the tolerances they can hit. If they don't meet those I'd love to hear it but if the laser cutting service is correctly advertised as being not quite as precise as precision machining, they're just being... honest. Which is good. And so are you. Which is good. 🤷🏼‍♀️

[@martindusek6329]

Hi James, would you create metric drawings of your belt grinder for people outside the US?

[@andarkelorin8797]

James, fantastic design, and I appreciate your comment about getting to a functional starting point and worrying about the accessories later. Too often people sacrifice good in the name of perfection and end up with nothing. I do have a question: Why did you opt for a nut on your tracking lever vs. threading the shoulder bolt into the yoke? In no way am I criticizing, just curious about your reasoning. Thanks!

[@Clough42]

I wanted the ground shoulder of the bolt to bear on a reamed hole at both ends instead of counting on the threads as a locating feature. Also, this way the nylon lock nut shouldn't come off, even if the bolt vibrates around and rotates.

[@andarkelorin8797]

@@Clough42 That totally makes sense. Thanks!

[@jamesdepaul3410]

Do you have plans / dementions available?

[@DavidHerscher]

“Metal Eraser” Damnit, that’s brilliant. I may very likely use that in the future, and pretend like you didn’t come up with it first. As a matter of fact, I’ve already begun “forgetting”…

[@nikonshooter71]

Will you be able to rotate your grinder ?

[@kentswan3230]

I must have missed it. Have you gone over how you adjust the tension and belt tracking so that it remains centered as your pulley surfaces appear to be flat rather than slightly crowned? I really like the visual appearance of this design and am wondering how to do one for myself even though I don't have a mill and lathe. To that end at the end of this series could you review your materiel and outsourced cost estimates as the shop time for most of us is 'personal hobby' time.

[@Clough42]

The drive and tracking pulleys are crowned.

[@kentswan3230]

@@Clough42 Thanks. Sorry about being dense. Caught that on the second watching. Thanks. Looks magnificent.

[@Mtaalas]

You don't build things because it's cheaper, you build stuff because it's FUN! (Except my studio table... I saved like 1400€ because I designed and built it myself... and back then I had more time than money)

[@J0Gu7]

Oh, it's gonna grind!

[@themechanicdrredewaan5916]

Hi, link for the plans please.

[@Machine_NZ]

Hi James, are the plans available and how much please? Regards Kevin

[@kensherwin4544]

He mentioned they're on his Patreon space and free to patrons.

[@gacherumburu9958]

👍👍

[@alanjackson4397]

👍

[@Trainwreck1123]

Can I ask what those little bottles you keep your cutting oil in are called? I've looked off and on for them and can never seem to use the right search terms to find them!

[@SuperGleep]

Look for "Spillmaster"

[@michaelstump6933]

I replied to this three times in a row with the brand name and all three times, my comment was immediately deleted. Strange. Let's try it this way. Search for this word with all of the spaces removed: s p i l l m a s t e r

[@bobvines00]

@@michaelstump6933 Try mispelling the brand name in an obvious manner. That might work. I hope that you are successful because I'm sure that many want the same useful information!

[@michaelstump6933]

@Bob Vines Hi Bob...just edited my comment with spaces in the name. Hopefully that sticks! I agree that those containers can be tough to search for. I think it's the last two syllables of the name that may be what YT had an issue with.

[@Clough42]

The cups with the brushes are Spillmaster containers. I got them from my local tool supplier, but some of the Internet tool suppliers have them. The pump oilers are from Goldenrod.

[@foolio42]

Turning off that distance to go beep was the very first setting change I made on my mill. :-)

[@Clough42]

It isn't mentioned at all in the EL400 manual, but DRO Pros has a document showing how to reconfigure it.

[@foolio42]

@@Clough42 I think that is where I found the answer, too. I am not sure because I turned it off two years ago and have never wanted to turn it on again. I have a printed version of the page stashed in case of factory reset or something.

[@ncut5547]

We use to use kerosene when turning aluminum I know its not the best choice but it use to work so good luv the build awesome job thks for the content much appreciated..

[@troyam6607]

the beep? nothing a hammer couldnt fix 😜 new build series!

[@Clough42]

DRO Pros to the rescue: www.dropros.com/documents/EL400ZeroBeep.pdf

[@troyam6607]

@@Clough42 cop out! aha well done

[@wags9777]

Just the tip and just for a minute

[@TheUncleRuckus]

Looks great James!! 👍👍 I can't believe some douche bag was complaining you weren't shilling enough. 😂 Goes to show that ppl will complain about just about anything. Keep up the great work!

[@MikeG-js1jt]

I'd be looking for a wire to that DRO beeper...........

[@Clough42]

I turns out it's configurable. DRO Pros sent me the instructions when I asked.

[@GR-hk4vd]

Damn, I want to build this, but after looking at the files, there are a lot of the machined parts missing that I have no way to fabricate :/

[@kohngaa]

James, your videos and calm delivery are always a joy to watch. I'm a garage woodworker, not a machinist but hey, anything shop or tools related - I'm in. Towards the end your little Harbor Freight Arbor Press looks like something I could use. I'm refurbing my dad's early 70's Craftsman 10" table saw and have come across a 1/2" shaft, 6" long with the final 1" turned down and threaded 3/8 16. The shaft is straight but that 1" of threads are slightly cocked at an angle. I've just searched the HF website for a small press like you showed but don't see one. Do you know if its still available? I suppose I could try a few local mechanics to see if they have a press and be willing to tweak this for me. Thanks!

[@Clough42]

The one I have is the half-ton model. I don't see them at HF any longer, either, but they're all over Amazon under various brand names.

[@VanguardSys]

like the videos! though again - for the exercise its great - for making parts - ehhh - i rather purchase a ready made unit for $2500 and make parts and money - i dont need projects anymore - all perspective - my 2 Brooklyn cents! keep the videos coming - great job!

[@Clough42]

I think that's totally reasonable. If you're making parts and money with your time, dropping the coin for something ready to run makes sense.

[@VanguardSys]

@@Clough42 thanks for responding - and everything is very clean/neat and has a place! love it!

[@0ADVISOR0]

Hey James, awesome build! Do you accept viewer mail? Greets from Germany

[@thomasquinn421]

I think the commenter on the previous video was saying that laser-perfect and mill-perfect are two separate standards. It wasn’t fair to judge the laser parts to machine shop standards. I kinda thought the same thing as a laser operator

[@samjackson8222]

You don't seem to use your cnc mill anymore...

[@Clough42]

It hasn't appeared in a video recently, if that's what you mean.

[@larspetersen2688]

Hello James. I have been following your projects for some time and admire your skills. Regarding your belt grinder project, you had set up some parameters for your design. I believe that in this case you have neglected the most important parameter. "security"!!! I have seen many belt grinder designs, unfortunately for all of them, no one thinks about safety. no one has a thought on how to catch the grinding dust there are throws around in all directions. In my opinion, this is a huge mistake. And yes your machine looks great and I'm sure it will grind well , but without any dust collection*S* Am working on a design myself, and this dust collection isue is not an easy task to solve but think it is a must!!

[@bobvines00]

I've seen water cans installed immediately under these grinders to catch the "downward" sparks - they work well. I also agree to the need for proper dust collection.

[@Clough42]

The design is intended to be modular. I have a bunch of ideas for dust collection, articulated tool rests, pivoting to horizontal, etc. But the fact of the matter is that none of those do any good if I keep designing it forever. I had to pick a point to start building. That other stuff will come if and when I have the need for it and have time to work on it. Dust containment is probably going to end up being high on the list if I find myself using it a lot.

[@joell439]

​@@Clough42 James, I have no doubt with as clean and orderly you prefer everything, you already have a clever design in mind. But if it helps..... You might consider using a restaurant 1/3-Size or 1/4-Size, 6 Inch Deep Stainless Steel Steam Table Pan to catch the grinding dust. It has worked wonders for me on the 2x72 grinder I built. I fill it about halfway with water and position it just under the lower platen wheel. Catches almost all the debris and the 1/3-size pan is long enough to allow access for dunking and cooling the item i'm grinding too.

[@mjc2ride336]

Lock your X and Y ways to stop the beeping.

[@Clough42]

Even turning the locking lever will move the table a tenth.

[@dkerekes1987]

Could you add a clip into your video's for a cost breakdown i would love to see that. Considering joining patreon for this project alone! Very cool! Cant imagine the feeling. Also Thanks for all that you do!

[@gregfeneis609]

INB4: "I love it when a plan comes together" ?

[@gregfeneis609]

Nope. 9 comments down

[@bobweiram6321]

When I heard $2K, I nearly coughed myself to death from accidentally inhaling the smoke from my Cohiba.

[@Clough42]

Doing some looking around, I see bare bones import machines for $1100-1200. Solid commercial grinders from places like Diktator and Alec Steele are well north of $2K.

[@AttilaAsztalos]

Meanwhile, us mere mortals in Eastern Europe just get the $150 import machine.

[@chrisH-uv5wx]

Either 2k for a grinder or 2k for a box of Cohibas. Take your pick

[@WireWeHere]

Swapped out many beep beep #@&$ beeps for a light wait assistant.

[@Clough42]

I was surprised to find that there isn't a setting to turn it off. Sounds like someone is going to need to get in there with a soldering iron.

[@Clough42]

And...a little more searching turns up a solution from DRO Pros: www.dropros.com/documents/EL400ZeroBeep.pdf

[@bigworld7514]

👍👍👍👏👏👏🤝🤝🤝🇧🇷🇧🇷🇧🇷

[@williamlanphar630]

A very nice unit....not $2,000 nice....but nice none the less.

[@kurtbilinski1723]

Have you ever fully machined a part, got it all done except for tapping, then used the wrong thread tap? No, neither have I...

[@Bosbulls]

I am not sure who copied whom, but those strap clamps that you copied from Tom, looks exactly like the clamps that Joe Piezinsky is using. But in any case most of the "home built" tools are copied and improved from someone else.

[@Clough42]

I always try to steal my ideas from the best.

[@INSIDEHARDWARE]

Hah… golly… $2k

[@woodscreekworkshop9939]

First? 😆

[@_AvaGlass]

What a quality comment. Thank you for your valuable contribution.

[@Clough42]

Sure looks like it. Achievement unlocked.

[@negativeview]

That was a weird statement about send cut send. If anything, you acknowledging that it's not perfect makes everything else you said more trustworthy. Sponsors should WANT a trustworthy spokesperson. If you had said it was perfect, I wouldn't believe anything you said about the sponsor because it'd be obvious you weren't being truthful.

[@user-zu2bw7ig5v]

Too much talk not enough action.

[@seabreezecoffeeroasters7994]

For the Beeper suggest a lit latching pushbutton common in medical gear for this purpose. Lit when muted dark as 'normal', personally I would like just remove the buzzer 😆

[@Clough42]

I just checked the manual, and they just proudly proclaim that they have a near-zero warning function. No mention of any ability to turn it off. :(

[@Clough42]

Spoke too soon. DRO Pros has a document about this: www.dropros.com/documents/EL400ZeroBeep.pdf

[@seabreezecoffeeroasters7994]

@@Clough42 Easy then :)

[@joell439]

@@Clough42 👍👍😎👍👍

[@medienmond]

I saw that you have a keyless drill chuck. What do you use to really clamp this chuck down? There should be a tool for that. I have a Röhm Supra SK and a bosch chuck with three holes of 6mm at the bottom with a diameter of 39mm (Bosch)/40mm (Röhm) and 2 holes of 6mm at the top with 42mm diameter (only Bosch, Röhm has a 19mm nut on top). I really want to have a tool to clamp my chuck sometimes a littlebit more than only by my quite strong right hand ✋,🫣. Can you help me out with that information deficit?

[@Clough42]

The tool you want is called a hook spanner.

[@medienmond]

@@Clough42 Thank you very much. Just ordered two.