Angle grinder guide

Description

These are some of the parts required to build an angle grinder guide rail assembly. I wanted a tool to assist in cutting small (1.2mm) thickness metal plate. Was finding my grinding lines could easily wander. The assembly is designed with supported rail, SBR12 along with the rail slider blocks SC12UU. Different manufacturers will have slightly differing dimensions to their hardware so worth double checking the measurements of your hardware. The length of rail used is user choice. However, using the rail will have a certain degree of flex over its length, which will increase with longer models. Larger diameter rail will lessen this effect (but that's a whole new design). This is a guide rail, the operative word being GUIDE, it is not designed to handle any large forces, small cuts are necessary, even if, it takes longer to cut through the material. disclaimer 1 These files are provided as a base for further development of the idea. It is up to the user how he/she proceeds with the development. Files:- Grinder guide assembly - assembled (jpg file) - This shows the major components only. Fixing screws and bolts are not shown. Grinder guide assembly - exploded view - just as the file name suggests, the exploded view of the major components only. Drilling guide 1 - Rail end face, this is used to accurately drill a hole for tapping in the end face of the SBR12 rail. A 4mm metric tapped hole was chosen. Drilling guide 2 - Rail mounting fixed, this is used to locate and drill the 4off holes for mounting the rails to the support legs. 4mm machine screws were used in the final assembly. Drilling guide 3 - Rail mounting sliding, this was not used in the initial assembly. It is provided to allow for extending the rails further out from the support legs, an overhang if you wish. It would allow for a slightly longer cutting ability. SRB12-700 - This is just an example file of the linear rail that was used. It is not meant to be printed. The rail will have to be purchased, along with the sliding blocks. The rail I used was cut to a 700mm length. This could be a custom size depending upon the requirements at the time. Rail bracket - The main bracket for holding both linear rails. The fixing holes for the brackets will be tight, either redrill or just force the 4mm screw through. This one has plain holes in the base for fixing to your chosen platform. Mounting plate - This is for mounting onto the sliding blocks and provides a platform to mount your angle grinder. The holes for mounting onto the sliding blocks are 5mm countersunk. 5mm countersunk machine screws, about 10mm long were used to fix this in position. A 10mm hole was chosen for the main fixing bolt. On the underside a recessed area is provided to mount a thrust ball bearing, 51100, 10mm x 24mm x 9mm. The upper side has a location ring for the mounting of needle roller bearing AXK2542, 25mm x 42mm x 2mm. It may be necessary to run a drill through the 5mm and 10mm holes for any clearance that is required during assembly, these printed tight, but rather finalise with a drill than go for more clearance during the print. Mounting plate with centre support - this is the same as the mounting plate but with the addition of a centre support for the recessed bearing area to prevent some sagging of the filament as it was printed. If this doesn't work, separate support may have to be added via your slicing application. Grinder mount - This mount was designed for the Dewalt grinder and as such, other makes/models may not fit. There is, of course, the option to create your own or modify existing model. If this is printed pivot face down, then supports will have to be added via your slicing program. Additional hardware:- 4off M4 x 10mm (length depends upon drill/tap depth). Cap head screws. For end rail stop blocks. 16off M4 x 16mm screws, pan head or cap head screws, for fixing the rails onto the rail bracket supports. (complete with nuts/washers) Screws for fixing the rail bracket supports onto your chosen base. Flat head screws as the fixing holes have not been countersunk. 16off M5 x 10mm countersunk machine screws. For fixing the mounting plate onto the sliding blocks. 1off M10 x 40 bolt or screwed rod, along with washers where necessary. This is the main pivot bolt. Ball thrust bearing - 10mm x 24mm x 9mm. This bearing is mounted on the "back side" of the mounting plate, Bearing designation, 51100. Roller thrust bearing - 25mm x 42mm x 2mm. This bearing is mounted between the mounting plate and the grinder mount. Obtain one complete with the "washers", these will add another 2mm (total) to the thickness. Bearing designation AXK2542. 2off M8 x 20 bolts and washers for attaching the grinder to the mount. disclaimer 2 Only use this model if you are happy with the design and are aware of the safety requirements of using power tools. Printed parts can vary in quality, ensure the parts are fit for purpose. The grinder will need to be adjusted to give the correct cutting angle / angle of attack otherwise damage/injuries are possible. Modification of prints may be necessary to ensure safe operation. Capability and capacities are user discretion, ensure you are happy with the items provided, or use the idea to design your own. I am not responsible for people being stupid. EDIT 08/03/19 Added the sketchup make 2017 file for the assembly. This contains the major components available to edit if your using sketchup 2017 or above. Version 1 and version 2 of the rail bracket is included. Version 2 was made to increase stiffness of the upper linear rail. I have not tested this as only used version 1 in the original build, and while it is OK for me at this moment in time I did see an area for improvement. Did detect some flexing with version 1 if enough pressure was applied sideways. The "work in progress" has been removed. I do not envisage any more modifications to the items. Only time will tell if any parts are in need of improvement. Only thing is alternative grinder mounts, or a universal style. If anybody Alters, adds or improves the design, please post the files and give the community, and me :) a shout to check them out and possibly put them to use some time down the line :) Thanks.

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