BJansen 

‐ Ultimate 2x72 Belt Grinder Note:  Prices of metal fluctuate
significantly.  Xometry.com or sometimes 
Onlinemetals.com is often the cheapest ‐
Metals Listing 
make sure and search for coupon codes
You can buy from OnlineMetals ‐ or various other cut to size  Part Name/Use
Quantity
providers Total Price
1/2" x 8" x 20" 6061-T6511 Aluminum flat bar Main body 1 $             38.23
1/2" x 8" x 8" 6061 - T6511 Aluminum flat bar Left side body plate 1 $             14.58
1/2" x 8" x 12" 6061-T6511 Aluminum flat bar Base mounting plate 1 $             14.04
1-1/8" x 4" 6061-T6511 Aluminum round bar rod Handle 1 $               1.30
1/2" x 2-1/2" x 8.5" 6061-T6511 Aluminum flat bar Riser pieces 2 $               6.48
1-1/2"x 3" x 8" 6061-T6511 Aluminum flat bar Base mount 1 $               8.75
1/2" x 1-1/2" x 12" 6061-T6511 Aluminum flat bar Handle riser 1 $               1.94
1" x 1-1/2" x 8" 6061-T6511 Aluminum flat bar Top spacer 1 $               7.00
3/4" x 1-1/2" x 8" 6061-T6511 Aluminum flat bar Tool bar hole spacers 2 $               9.00
3/4" x 1-1/2" x 2" 6061-T6511 Aluminum flat bar Tracking mechanism swivel mount 1 $               1.08
1" x 2" x 8.5" 6061-T6511 Aluminum flat bar Tracking mechanism arm 1 $               5.18
3/4" x 1" x 2" 6061-T6511 Aluminum flat bar Tracking mechanism mounting tabs 2 $               2.00
Aluminum tube .26" ID, .50 OD 1 1/8" long Riser pieces spacers 4 $               6.00
3/8" x 2" x 6" 1018 Steel flat bar (size the rest to your liking) Tool rest plate 1 $               6.41
1-1/2" Aluminum 6061 Square Bar - 18" Length (I typically buy a 36" bar and cut a Tool bar arms
13-16" piece off to use as the platen tool arm and the longer remaining section to
use as the work rest tool arm). 2 $             26.40
Shipping $             30.00
Total Metal Cost $           178.39

Major Parts
Part Name/Use Quantity Total Price
Tracking wheel (Ebay ‐ Ameribrade is a good choice) Tracking wheel 1 $             30.00
Drive wheel (Ameribrade or any other ebay seller) Drive wheel
Notes :  Buy your motor first and then match the drive wheel to the shaft 
size of your motor.  Buy a drive wheel size that is suited for your motor 
speed.  If you are building a general use, variable speed grinder I would 
suggest a 5" or 6" drive wheel. If you are building a single speed general use 
grinder (3600 rpm motor) I would suggest getting a 4" drive wheel. 1 $             55.00
Motor‐ (find one on ebay) Motor

Notes: Ideally you will be building a variable speed grinder which 
requires a VFD and a 3 phase motor.  Search ebay for a 3‐phase, 208‐
230v, 1750RPM motor  anywhere from 1‐3HP.  The motor needs to 
have a c face such as the following types of baldor motors (VM3554 
or VEM3554, VM3558 or VEM3558).  The frame size needs to ideally 
be 145TC or 56C. This specific item may take a bit of homework and 
searching, but you can save a bunch of money on this specific piece 
rather than buying a brand new motor.  I have purchased several 
Baldor motors on ebay (in new or near new condition) priced 
between $65 and $200, depending on HP, shipping included. I am 
certain you can find a good motor for $150.

Single Phase Motor Notes: 
For a single phase motor, again find a 56C or 145TC frame size and 
3450 or 3600 RPM.  When using single phase for a general purpose 
grinder, I typically run a 4" drive wheel on a 3450 or 3600 RPM motor ‐
this combo gives you a belt speed of about 3700 surface feet per 
minute which is good for general purpose tasks.  You can run a 1.5HP 
motor on a 20 AMP 110V circuit and you can run a 2HP or 3HP single 
phase motor on a 220V circuit (so make sure you are thinking about 
your power source when purchasing the motor).   1 $           150.00
Only needed for a variable speed grinder (for use with your 3 phase  VFD
motor) KB Electronics KBAC 29D‐ Variable Frequency Drive ‐  Fwd 
reverse switch, line switch.  The KBAC 29 will run up to a 3HP motor, 
a KBAC 27 will run up to a 2HPa and a KBAC 24D ill run up to a 1HP 
motor.  The last KBAC 29D I purchased was from Texas Process for 
$345 ‐ shipped.  The forward stop reverse switch and line on/off 
switch will cost you another $50 and can be bought from a number of 
different sellers.  1 $           400.00
Electric supply: cords, wire & liquid tite fittings for VFD to motor  Misc. Electrical cords

(Note: For the VFD to the motor, you will need 14 gauge, 4 strand 
power supply wire (McMaster Carr has this ‐ so does Home Depot).  
The Power supply cord will depend on whether you are running 110v 
or 220v, and these supply cords can be found in any hardware store. 
Amazon.com has cheap liquid tight fittings. 1 $             50.00
Contact wheel or platen:  This is where you can decide how you  Contact wheel

would like to set up your grinder.  If you would like a contact wheel, 
they can be purchased from many suppliers and bolted to your tool 
arm.  I often buy my contact wheels from AliExpress (specifically a 
Rams Bralin contact wheel).  The quality is decent, and price is very 
good.  They sell all sizes and can install 1/2" bearings, or you can buy 
them ready for bearings and install your own.  Ameribrade also has 
good contact wheels (which I think are the same Chinese wheels, 
with better bearings and balanced).  If you are looking for a flat 
platen, they are easy to make your self and also available from many 
sellers ‐ just do a search, find one you like and bolt it on your tool 
arm.   1 $             65.00

Hardware
Gas Spring with Ball‐Joint End Fitting, 40 lb. Force, 12.2" Extended  Gas Shock

Length   McMaster Carr # 4138T54 1 $             17.00
Gas Spring mounting bracket McMaster Carr # 9512K95 Gas shock mounting bracket 1 $               2.00
10‐24 x 3/8" long socket cap screws ‐ McMaster Carr or hardware  Gas shock bracket mounting screws

store 2 $               1.00
Die Cast Zinc Adjustable Handle, 5/16"‐18 Thread x 1‐3/16" Long  Locking handles

Stud, 2‐9/16" Long Handle  McMaster Carr # 6271K22 2 $             16.52
2.5" Stainless flat cap bolts ‐ 1/4"‐20   10 pack ‐  McMaster Carr Assembly bolts 2 packs $             12.42
1 1/4" Stainless flat cap bolts ‐ 1/4"‐20 ‐ 25 Pack   ‐  McMaster Carr   Assembly bolts 1 pack $               6.01
Shoulder Screw, 3/8" Diameter x 1‐3/4" Long Shoulder, 5/16"‐18  Shoulder bolt for tracking arm bar

Thread  ‐ McMaster Carr  # 91259A630   1 $               1.70

PTFE Thrust Bearing for 3/8" Shaft Diameter, 3/4" OD, 1/16"  Bearings for tracking arm

Thickness  McMaster Carr #2796T12 2 $               3.96
Lubricant‐Filled Nylon Plastic Washer, .322 ID ‐  They come in packs  Nylon washer for tracking tab

of 5 (you only need 2 individual washers)  McmasterCarr  # 
91545A260 1 pack $               2.54
18‐8 Stainless Steel Shoulder Screw, 5/16" Diameter x 2.5" Long Shoulder,  Shoulder bolt for tracking tab
1/4"‐20 Thread        McMaster Carr # 91259A109
1 $               5.10
18‐8 Stainless Steel Shim, .020" Thick, 1/4" ID, 3/8" OD, packs of 10 ‐  Shim washers (to properly space tool
bar openings)
McMaster Carr #98126A568 (you will need exactly 12 shims) 2 packs $               7.58
Tracking wheel bolt

4"  1/2‐13 thread bolt, nut ‐  McMaster Carr or local hardware store 1 $               2.00
 Iron Knob with 5/16"‐18 Thread 3" Long Stud   McMaster Carr #  Tracking adjustment screw

6042K88 1 $               8.70
3/8" SS bolts, 1" long and washers    McMaster Carr or local hardware  Motor mount bolts
store 4 $               5.00
Steel Thrd‐locking Slotted Thick Wall Insert, 5/16"‐18 Int Thread,  Steel threaded inserts for tool bar
locking handles
31/64" Length (McMaster Carr # 90248A027 ) 1 10.25
Shipping $             15.00
Total Accessory/Hardware costs $                 867

All in grinder cost $             1,045
Approx build time:   about 10‐15 hours
8.5" x 14"
1-------- 7, 7.r:;'' --------f - 1.5'1- I (

I /z. 1t ;< <l' 'f -zo ''

{rL,
If you need help or have questions, I can generally be reached at 618-579-9689 on weeknights between
8PM and 9PM CST.
BJANSEN'S ULTMATE BELT GRINDER 2019 =
BASE PLATE
1:2
1/2 X 8 X 14 Aluminum
Page 1 of 12
NOTE: Dimensions given for most unthreaded holes are for associated hardware, not clearance hole sizes

These PDF drawings were graciously provided by my buddy Fittzhugh

.5

.75 .75

4X Ø.375

4X Ø1/4-20
82° Ø.56

8 .75

2 2 2 1

3.625

14
 BOTTOM SPACER
1:1
1.5 x 3 x 8 Aluminum
Page 2 of 12

1.5
.5 3.5 3.5

3X Ø17/64
<.5
NOTE: Transfer holes from LEFT SIDE PLATE
to account for toolbar clearance, as set by
3 temporary tape shims - see instructions.

1 2 2 2

4X Ø1/4-20 1
.375

.375

8
MIDDLE SPACERS (2 REQ)
1:1
3/4 X 1.5 X 8 Aluminum
Page 3 of 12

1.5

.5 3.5 3.5

3X Ø17/64
.75
~.375 (SEE NOTE)

NOTE: Transfer holes from LEFT SIDE PLATE

TRACKING SUPPORT SPACERS (4 REQ) to account for toolbar clearance, as set by
temporary tape shims - see instructions.
1:1
0.26 ID 0.5 OD X 1.125 Aluminum Tube

1.125
Ø.5

Ø.26
TOP SPACERS
1:1
1 X 1.5 X 8 Aluminum
Page 4 of 12

2X Ø#10-24 .5

1.5

.75

2 1

.5 3.5 3.5

.5
1
3X Ø17/64
SIDE PLATE, RIGHT
1:2
1/2 X 8 X 20 Aluminum
Page 5 of 12

3.25 1.5 11.25

.5 .5

1.125
12X Ø1/4-20
2.375

A 4X Ø1/4-20 A

2.25

4X Ø.375 8

4 Ø4.5
2.375

BOLT CIRCLE Ø5.875

3.5 3.5 .5

20

.5

SECTION A-A
SCALE 1:2
SIDE PLATE, LEFT
1:2
1/2 X 8 X 8 Aluminum
Page 6 of 12

.5

1.75
2.25

2.25 2.375
4

12X Ø.25
82° Ø56
8 2.25

2.375
3X Ø1/2-13
1.75

.5 .5
4

.5

8
TENSION & TRACKING SUPPORT, RIGHT
1:1
1/2 X 2.5 X 8.5 Aluminum
Page 7 of 12

RELIEVE AS NEEDED
FOR MOTOR CLEARANCE

.5

Ø5/16-18

4X Ø.25

2.5

.5
1.25

.5 1.125

7.75

.5

8.5
TENSION & TRACKING SUPPORT, LEFT
1:1
1/2 X 2.5 X 8.5 Aluminum
Page 8 of 12

RELIEVE AS NEEDED
FOR MOTOR CLEARANCE

.5

Ø.375

4X Ø.25
82° Ø.56
2.5

.5
1.25

.5 1.125

7.75

.5

8.5
TENSION & TRACKING ARM
1:1
1 X 2 X 8.5 Aluminum
Page 9 of 12

75° .5
2.75 2.25

4X Ø1/4-20 2X Ø1/4-20
.75 82° Ø.56
1

1
.75 2
1.125
.875
Ø.375
75°
.6

Ø1/2-13 .5

8.5
TRACKING PIVOTS
1:1
Page 10 of 12

REAR PIVOT
3/4 X 1 X 2 Aluminum

FRONT PIVOT
3/4 X 1 X 2 Aluminum

.25
.75 Ø1/4-20

.3125
.75

.75 .25 2
.875
Ø.3125

.3125
.75

[SEE NOTE] 1
2
.875 2X Ø1/4-20 .75

NOTE: Assemble TRACKING PIVOTS, TRACKING TAB,

washers with shoulder bolt, then transfer hole locations
from TENSION ARM to account for washer thickness.

[SEE NOTE] 1

2X Ø1/4-20 .75
TRACKING WHEEL TAB TRACKING COMPONENTS ASSEMBLED
1:1
3/4 X 1.5 X 2 Aluminum
Page 11 of 12

.5

PLASTIC WASHERS
.3125

Ø.3125

Ø1/2-13 ~.75

2
1.5

.6

.75 1.5

~1.568

2.25
TENSION HANDLE ARM
1:2
1/2 X 1.5 X 12 Aluminum
Page 12 of 12

11.25

~6.75
SEE BUILD-ALONG FOR LOCATION DETAILS

Ø5/16-18 2X Ø.25
.75
1.5 82° Ø.56
Ø1/4-20

.5 75°

.5

12
LEFT SIDE AND SPACERS
Front View
1:1 .5
Transfer holes from side plate to
spacers, using tool bar with
temporary tape shims to ensure
clearance for tool bar movement.
See instructions for details. [ 1.5 +
thickness of
temporary [ ~.375 - shim thickness.
tape shim ] Transfer from
LEFT SIDE PLATE ]

[1.5 +
thickness of
temporary
tape shim] [ ~.375 - 2x shim thickness.
Transfer from
LEFT SIDE PLATE ]

[ 1.5 +
thickness of
temporary
tape shim ] [ ~.5 - 3x shim thickness.
Transfer from
LEFT SIDE PLATE ]

.02
Offset
by shims