I can't take any credit for this idea at all-came from Bruce Bingenheimer. I tend to be a bit "economical" (some have termed it "cheap"...) and this setup makes life for a guy like me way better. Since getting to use Bruce's disc sander, I saw the REALLY great things I could do with it, and his way of doing things made it possible to use the same motor and VFD I already had, making it cost very little. That, coupled with the space saving in an already crowded shop area is a winner. Sorry for the blurry cell photo...
I ordered a keyed shaft from MSC to replace the original that came with the KMG, just longer. I got a disc and a friend helped me turn down one end of the shaft to fit the disc and mill in the keyway. Figured a pillow block out on the end would be beneficial to help keep down any deflection on the shaft. I still need to align and tighten everything down, shim up the pillow block and bolt it down, etc. I also have plans to make a table that will go about half way across the disc (since you're only using the downhill side, anyway). Oh, and I found and ordered the forward/stop/reverse switch for my KBAC27D, which works very well, too. I picked up a roll of 1/16" thick cork gasket material from the auto supply store and will be using spray adhesive to permanently attach that to the disc. Think I may cut a strip and try on a sanding stick, too...
Now I just need to cut out the portion of wall to the left of the disc so I can work material off that side and move my belts to a new location. All in all, I can't wait to start using it <img src=' http://www.americanbladesmith.com/ipboard/public/style_emoticons//smile.gi f' class='bbc_emoticon' alt=':)' />.
Jeremy
Jeremy Lindley, Apprentice Smith
Jeremy,
That looks great! I was going to try that too, but when I received my disc and tried it out it wobbled so badly I couldn't have used it at all (and that was mounted directly to the motor that came with my KMG!) When I sent it back and asked the supplier of the disc why, he said he inspected it and they all do it some. I couldn't imagine that it would be of any use to anyone with the surface of the disc wobbling in & out, so I bailed on the idea. I still have the reversing switch installed, so if you can give me some advice on this, I would really appreciate it.
Ed-
How much play did yours have? When I used Brice's, it had a bit and he was the one who suggested I use a pillow block to help. His was mounted on the drive wheel side and didn't stick out all that far. Because of the placement of mine, I needed to go to the opposite side, so I was going to have a ways between the drive belt and actual disc (just measured-10" from belt to disc face). Just to see, I turned on the grinder before mounting the disc and pillow block-there was very little wobble of the shaft end at all. Same thing after I got it all put together. Put on some paper last night just to give it a try and it went well.
One thing to look at is the fit of the disc to the shaft. I ordered the 2' shaft and the first time my friend turned it down for the disc, there was a slight amount of space-just enough for it to wobble a tiny bit. He pointed out that once turning, it could do the same, even though the set screw would be tight. We cut it off and turned it again, this time it had to be coaxed on just a bit-a very nice fit. Looking at it all now, I'm convinced if the disc is just a little bit loose on the shaft, it'll have much more play when in use.
And for what it's worth, I got the disc and pillow block from Beaumont metal's website. Not sure the disc manufacturing has much to do with it, but it seems mine is quite true. I'm not even certain how necessary the pillow block is, but I know it couldn't hurt, especially if I put much pressure on the edge of the disc while grinding. Hope that helps.
Jeremy
Edited to add: Though Bruce's had some wobble, it was still definitely usable. It cleaned up some facets I had made with my belt grinder very nicely. One of the nicest things about the disc is it quickly shows where you're off and can get it flat without much effort.
Jeremy Lindley, Apprentice Smith
Jeremy,
Mine wobbled alot even though it was mounted directly on the motor shaft. It did not fit snug on the shaft, and I thought that was the problem. Unfortunately, I don't have access to a lathe, so I'll have to figure out another way, I guess.
I bought mine from Beaumont Metal Works, and the disc runs perfectly smooth. I think it was around $1000 after shipping.
