How to make a cutting machine from a grinder yourself

It is difficult to cut a large number of small pieces with a grinder. The cutting disc moves to the side, causing the cut to be uneven. A machine will help simplify the task. Its design is so simple that craftsmen do not want to pay a lot of money for a factory-made product. Having the drawings at hand, you can assemble a cutting machine from a grinder with your own hands without much difficulty.

Why make a machine from an angle grinder

A cutting machine is a useful and necessary thing, not only in industrial conditions, but also in the household. With this useful tool you can make precise cuts of parts and workpieces. This is achieved by securely fixing the cutting disc, into the spindle of which you can install not only abrasive wheels for cutting metal. A stationary machine can be used for cutting tiles, bricks, marble, granite and other similar materials, using special diamond-coated wheels in the design of the tool. If necessary, such a machine can be used for sawing beams, boards and other wood workpieces.

Many people who have repeatedly faced the need to make an accurate cut of a workpiece want to know how to make their own cutting machine from an angle grinder and available materials. Holding the grinder in your hands, you can also make a precise cut, but it is more difficult to do this, since you have to hold the tool exclusively with both hands. Using a homemade cutting machine, you can not only perform, but also simplify the following work:

Cut sheet material, such as galvanizing, used for chimney insulation and other purposes
Cut ceramic tiles and tiles - keep in mind that the cut can only be made straight
Cut materials at different angles
Cut a metal profile, pipe, wooden beams, boards, etc.

The manufacture of a machine from a grinder requires an appropriate approach. After all, the tool itself is very dangerous, so the slightest miscalculation can lead to the master being seriously injured. The consequences of working with an angle grinder if safety regulations are not observed are known, so first, before building a homemade product, it is worth noting the following:

Only with the correct manufacture of a stationary cutting machine can you be confident in its reliability and safety
If you plan to do it, then you need to calculate every step so that no disaster happens during operation.
Using a machine is in some ways safer than using a tool while holding it in your hands. However, you need to be aware that an angle grinder is a mobile tool, and making a homemade one is already a violation of safety regulations
For manufacturing, it is necessary to use materials of appropriate reliability, corresponding to the power and size of the main power tool.

Having dealt with the need to manufacture the machine, you can get down to business.

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If you can’t decide whether it’s better to buy a new machine or make it yourself, then the second option is more preferable, since the cost of a factory device will cost at least 10,000 rubles. If you make it yourself, you won’t need any expenses, since the grinder is already on the household, and the components can be found in the garage.

Required tools and materials

To make a cutting stand you will need power tools:

Grinder for cutting metal blanks.
Drill, used for drilling holes.
Jigsaw. It is used to cut plywood for the base. You can also use sheet metal for this part.

Hand tools are also used, without which it is impossible to carry out work:

Roulette.
Pencil or marker.
Corner.
Set of drills.
A set of spanners or wrenches.
Pliers.

Making a homemade machine from a grinder features

It’s not difficult to make your own machine from a grinder yourself. Moreover, there is a wide variety of manufacturing options, which depends on the available materials and imagination. There are two types of stationary cutting machines made from grinders:

Simple - it received this name for one reason, which is not only the ease of manufacture, but also the minimalism of the device itself. The tool is attached to the workbench using additional materials, and it can be used
Complex - it is rational to manufacture such machines if you plan to use it often for different actions. In most cases, a simple device is enough for a home garage, the manufacture of which requires little time, effort and consumables.

In order to make a cutting machine from a grinder with your own hands, you will need consumables, which are metal plates, as well as profiles and fasteners - bolts, nuts and washers. The only specialized tools you will need are an electric drill and a welding machine. Let's look at how to make the simplest version of a cutting machine from an angle grinder in more detail below.

Option 1 - a simple way to make a cutting machine from an angle grinder

A simple way to make a homemade product involves making a base on which fixed connectors for a movable plate are attached. So, in more detail about how to make a machine from an angle grinder:

Take a steel plate measuring 15x15 cm and at least 2 mm thick. Such a large size is needed in order to secure it to the workbench with bolted connectors. If the workbench (table) is iron, then the base can be welded to it, so in this case you can use a shorter plate 10x10 cm
Weld two rectangular plates perpendicularly to the base, located at a distance of 5-8 cm from each other. The thickness of the plates should also be at least 2 mm. Their length depends on the size of the power tool, but usually small or medium grinders are used for stationary machines, so the length of the plates is 8-10 cm
At the base of the plates, make a straight hole into which the connecting bolt is installed. The hole diameter is 6-8 mm, which is not so important
At the next stage, you will need to make a movable base to which the grinder will be attached. To do this, you will need to take a steel plate at least 20-30 cm long, which depends on the size of the power tool. The width of this frame should be slightly less than the distance between the protrusions of the rectangular plates welded to the base
On the back side of the movable plate, you need to weld a round oblong sleeve into which the connecting bolt will be placed
It is necessary to secure the tool to the resulting movable plate using clamps, ties and other methods. The number of fasteners should be more than 2, and preferably at least three for greater safety
Having secured the resulting structure to the workbench, you can test its operation

For ease of operation, you can weld a handle to the movable bar, and also install an auto-return spring, which will return the tool to its original position, that is, move it up. The photo below shows a ready-made installation for cutting from an angle grinder. As you can see from the example, its manufacture will require a minimum of effort and materials, and the result is a stationary device for cutting various materials.

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Finally, you will need to cut a strip of the appropriate size in the workbench, into which the rotating circle in the tool chuck will “go” when cutting materials.
When constructing the device, do not forget that safe operation depends on how to secure the angle grinder. It should be securely fixed in 2-3 points, which will prevent it from moving during work, as well as “flying off” from the movable frame. When installing the tool on a movable bed, it is necessary that the position of the grinder be strictly at a right angle, that is, the circle must be located strictly in a vertical position.

The resulting device is suitable for processing various materials from wood to durable stone. When working with a tool, do not forget to use safety glasses, gloves, and protective clothing. Instead of a workbench, you can use a wooden or steel frame on which to realize your idea.

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Similar simple frames for grinders are manufactured in the factory, so if you have an extra 2-3 thousand rubles, you can purchase a ready-made base and use it right today. However, there are no difficulties in making it yourself, so you need to decide on your own in each individual case which is better.

Main components of the device

To make a stand for an angle grinder we will need the following parts:

support frame: it can be welded from profile pipes; such a design will have increased rigidity and not be afraid of vibration; when using wooden blocks, it is advisable to take hardwood;

Support frame

working platform (table cover) with mounting holes: it is made of sheet steel; You can also attach a sheet of cast iron from an old stove to the support frame - it drills easily and is not difficult to work with;
a vertical stand for attaching tools: for it we use two small pieces of steel corners with holes drilled in them; they are bolted to the grinder gearbox using the holes for the handle; for reliable fixation, we first lightly fasten the corners together by welding directly on the grinder, and then, after removing the tool, we finally weld them together;

Tool holder

a rotary lever with fastenings: we will describe the principle of its operation below;
quick-release vice for securing parts; since the thread on the stud quickly fails, we will make a clamp from an elongated nut cut in the shape of a semicircle, which is welded onto the stud; to make it heavier, we attach a small piece of metal to its opposite end, which will serve as a kind of paw for lifting the clamp;

Quick clamping vice

a rotary table for processing products of complex shapes: you can use a hub from a passenger car of a suitable size as it;

Rotary table

a ruler attached to the turntable: for simple work you can use a carpenter's goniometer; for precise measurements, a structure is assembled from a protractor and 2 machinist's rulers.

Option 2 - how to quickly and easily make a pendulum saw

If you have a welding machine and consumables, you can make a stationary machine from an angle grinder in a matter of hours. Moreover, you don’t need to buy anything for this, since the necessary tubes, fittings and profiles can be found in a garage or a pile of scrap metal. To build a simple cutting machine using an angle grinder as the main tool, you will need to use the following parts:

Metal profiles measuring 150-200 mm
Sleeve 10-15 cm long
Hairpin 20 cm long and 8-10 mm in diameter
Washers
Metal corner
A sheet of metal 2-3 mm thick, which will act as a base

So, to make a simple homemade product you will need to perform the following steps:

Cut the stud to the required length, then place the sleeve inside (it should move freely along the stud), and tighten the nuts onto the ends of the protruding stud. Tighten two nuts on both sides, since the second will act as a lock nut
The nuts should not be screwed in completely; they should not come into contact with the sleeve
The resulting structure should be welded to a steel sheet. In this case, it is important to grab the nuts, and the sleeve must remain mobile, that is, move freely
At the next stage, it is necessary to make mounts for the grinder. To do this, you will need metal profiles, as well as washers that will act as brackets
Cut to the required length (it all depends on the tool used, but for a low-power grinder, the profile length is 15-20 cm). Weld washers to the ends of the profiles. It is recommended to use at least 2 mounts for an angle grinder, but three is better
The angle grinder has threaded holes for connecting the handle. We use these holes to attach the tool to the movable base using pre-prepared brackets
First, the brackets are attached to the tool using bolted joints of the appropriate size, and then the reverse ends of the profiles are welded to the sleeve. As a result, we get a ready-made machine that can be produced literally within an hour

The photo below shows the design of a homemade machine made from a grinder with a detailed description of the necessary materials. Using the instructions, or for some, a diagram is enough to make a homemade cutting machine. It is important to take into account that a casing for an angle grinder must be provided, otherwise the risk of serious injury increases. Operating the tool without protective clothing, not only on a person, but also on the device itself, is strictly prohibited.

The simplest device is ready for use. The angle in the machine design is used as a guide for centering cutting materials. You also need to make a straight hole in the iron sheet, into which part of the disk will “go” when sawing workpieces.

Sheet steel cutting machine

The main parts of such a machine:

Base. Ideally, it should be no smaller than the sheet that is supposed to be cut with a grinder, or allow the entire cutting area to be laid on it. It is necessary to use steel as a manufacturing material so that it absorbs heat, preventing the steel cutting line from overheating.
U-shaped stand. This structural element serves as a guide for pulling the angle grinder through. The length of the section between the legs of the stand should be sufficient to place a sheet between them, plus allow the body of the angle grinder to fit freely.
The carriage is a movable element that moves along a U-shaped stand on bearings. A pendulum console and a depth limiter for lowering the cutting disc are attached to it.
The pendulum console serves as a mechanism for lowering the angle grinder to the level of the working position. Also attached to it is a tool control handle.

Option 3 - an even easier way to make a cutting machine from an angle grinder

Many people do not have welding machines or do not know how to use them, so if you belong to the category of these people, then you should not despair. There is also no need to ask your friends and neighbors to make a machine. It is quite possible to do without welding, and bolts and nuts will be used as the main connectors. So, to construct a simple cutting machine from a grinder, you will need the following consumables:

Corners - and a small number of them up to 1 meter. If there are pieces, that's even better. Corner thickness is standard 2-3 mm
Steel tube 30 cm long - will be used as a handle on which the grinder will be attached
Steel sheet 2-3 mm thick and of any size, but not less than 20x20 cm
Bolts with nuts with a diameter of 8-10 mm

Let's start making a homemade instrument. The manufacturing process is as follows:

First, you need to attach a 15 cm long corner to the steel sheet
Attach another corner perpendicularly to the wall of the lying corner using bolts and nuts. If there is welding, you can make tack welds
Attach the tube to the perpendicularly installed angle using the same bolted connections
The tube should move freely, so there is no need to tighten the nut on the bolt. Instead, you need to tighten the fixing bolt with another nut.
Connect two steel plates measuring 5x6 cm to the tube at a distance from the connection point. These plates will be used to attach the grinder to the handle
Attach the angle grinder to the casing with pre-prepared steel plates

As a result, we get a simple cutting machine, a photo of which can be seen below.

There are many options for manufacturing similar structures, so it all depends on what you want to get in the end and what consumables are available. Working with the version of the cutting machine discussed above is not entirely convenient, as it is necessary to constantly hold the tool (due to the lack of a return mechanism), but this is easy to fix. A spring must be attached to the protruding part of the tube, which will return the tool to its original position, eliminating the need for the master to hold the operating unit.

Should I buy or not?

Finding a ready-made machine on store shelves that at first glance satisfies your needs is a fairly simple task. But it is unlikely that there will be a design made entirely in accordance with your requirements, and they are different for everyone. In such cases, owners of machine tools try to improve or remodel them, but are faced with very serious obstacles - either the manufacturers made the machine from alloys that are very difficult to work with by welding, or they did not take into account the little things that you need specifically - for example, an accurate ruler or a more elastic spring. Remaking someone else's is much more difficult than making your own.

How to make a start button for a pendulum machine from an angle grinder

The angle grinder works when you press a button. Moreover, the spindle rotation speed depends directly on the pressing force of the button. This means that an adjustment mechanism is built into the button, the operation of which facilitates the operation of the tool. When operating an angle grinder on a stationary machine, it is necessary to consider the starting system so that you do not have to hold the handle with one hand and press the button with the other.

If the tool is equipped with a regular button, which automatically locks when it is turned on, as for example in the first version of the machine, then no difficulties arise here. First, the tool is turned on, and then you can perform work. However, most angle grinders are equipped with self-off buttons that must be held by hand while operating. There are two ways out of this situation:

Use ties (for example, plastic) or clamps of the appropriate diameter. They fix the button in the pressed position. In this case, it is also necessary to take into account the latch, which is responsible for turning the tool on automatically. Both the latch and the button must be tightened with a clamp, tie or other similar materials. In this case, the principle of operation of the device will be as follows - if you need to start the tool, you need to plug the plug into a socket or make a switch
It is rational to remake the starting system if the tool is planned to be used more often as a cutting machine than as a stand-alone angle grinder. To do this, it is necessary to route the wires from the angle grinder to a separate switch, which will turn the tool on and off if necessary.

The power button, if it is displayed, is best located on the handle. A homemade machine does not require large expenses for its production, which, in fact, is its main advantage.

Electrical part

Since the angle grinder is attached to the bottom, you cannot turn it on as usual. You will need to install:

A clamp that will hold the control key in the “on” position.
Socket for angle grinder.
A control station that turns on/off the electricity in the outlet.

Using an industrial station is an excellent solution, the device has a couple of keys, the start button is tight, which will protect against accidental activation. A large and convenient “stop” button will allow you to quickly turn off the device if necessary.

Important points when constructing a pendulum machine

The type of tool under consideration belongs to the category of dangerous, therefore, when constructing the equipment, the following main points are taken into account:

The manufacture of the frame is the basis responsible for the reliability of the installation. It is impossible to save on the manufacture of the frame, therefore only steel materials are used, the thickness of which is at least 2 mm
Frame - the design of this part can be different, but the most important thing is to ensure the mobility of the cutting tool. This is achieved through the use of different materials, but in any case, you need to think carefully about the quality of the hinge joint, since your life depends on it. It’s better to spend more material, but make a high-quality and safe cutting machine
Tool fastening - the angle grinder is fixed directly to the moving part. Moreover, the fixation must be as reliable and high-quality as possible. When working with an angle grinder, “reverse impacts” may occur, which are dangerous because the machine may simply be damaged, and the master who performs the manipulation will suffer as a result.
Providing a counterweight is a small but important element that allows the tool to return to its original position when not needed. This will eliminate the possibility of damage to parts of the human body
A protective casing - it must be present, no matter what design of the machine is invented, but using the device without a protective casing is strictly contraindicated
The presence of a ruler - this will increase the accuracy of the work performed, which is important when cutting parts such as tiles, ceramics, and metal
The starting device is also a kind of safety-affecting device. The control button should be located in close proximity to the master performing the work. This will allow you to quickly react at the right time by turning off the power supply to the tool.

In addition to options when the machine has a moving part, there are also methods for manufacturing cutting devices with the tool located in the lower part of the bed or workbench tabletop. However, this option is suitable only for cases when sawing wood is planned. Below is an example of how to make a home sawmill from a grinder quickly and easily. Details on making home sawmills can be found in this article.

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The tool can only be used in this form with disks or circles for processing wood. Cutting tiles and metal in this position of the grinder is extremely dangerous.

What are the advantages and disadvantages of homemade machines made from grinders?

The homemade products in question have some advantages and disadvantages, which everyone who has set out to make a cutting machine from an angle grinder also needs to know about. The advantages include:

Having a stationary machine in the garage, you can quickly, and most importantly, efficiently cut different materials
Obtaining a high-quality and even cut, which makes the device perfect
Cheap - if you have an angle grinder, then the cost of manufacturing the machine will be minimal

Now let’s find out what disadvantages the homemade device in question has:

Low reliability - even with the most competent approach, the possibility cannot be ruled out that a person may receive various injuries just because of working on such homemade equipment. To protect yourself, you need to work in protective clothing
The difficulty of transporting the device depends on its size and weight. Only if the machine is called stationary, then it is intended for use in only one place

If you have already managed to manufacture the type of equipment in question, then understanding the correct operation of it will not be difficult. Already from the first test of the tool you can feel how effective its work is. Below is a selection of photos showing options for homemade cutting machines from grinders. In addition, a tool such as an angle grinder is fraught with many interesting ideas for expanding functionality, but that’s a completely different story.

What exactly are we talking about?

There are dozens of traditional designs of units for precise cutting of sheet, roll and long materials, not counting lasers, etc. from the age of high technology. We will further consider machines with a swinging working module and a round rotating cutting element - an abrasive or saw blade. Such cutting machines are called pendulum. They are the most versatile (including suitable for broaching - making longitudinal cuts of limited length) and can be done independently in a shed and garage workshop. When they say “cutting machine,” in the vast majority of cases they mean a pendulum cut grinder.

Motor or angle grinder?

This refers to the machine drive - separate or combined in a monoblock with a working (cutting) element and a power transmission to it. A separate motor has the advantage that the swinging part of the unit - the rocker (pendulum, rocker arm) can be made properly balanced, which greatly simplifies the work on the machine and increases its productivity; the latter depends relatively weakly on the cutting resistance of the material

In addition, the entire machine can be made suitable for intensive round-shift work, which can be important for those who earn income with hands that grow in the right place and a head that works as it should. An angle grinder (grinder), as you know, can work continuously for 20-60 minutes

(depending on the model), and then forced technical downtime to cool down the instrument. But for occasional use, an angle grinder has a number of advantages:

A fairly durable and accurate cutting machine from a grinder can be made without turning parts and with a minimum of welding work or without it at all, see below.
The basic tool remains suitable for manual work outside the machine.
Power supply – single-phase 220 V from a household outlet.
Starting devices and protective grounding are not required, because Only angle grinders with double insulation are widely sold.
The external characteristic of the commutator electric motor of an angle grinder is softer than that of an asynchronous electric motor with a squirrel-cage rotor, which saves motor power and electricity consumption. In most cases (except for cutting thick, strong and/or viscous materials), we can assume that an 800 W electrical angle grinder is equivalent to an asynchronous motor with 1.2 kW on the shaft (see below), and a 1300 W angle grinder is equivalent to a separate 2.0 kW motor. 2 kW.
Cutting machines made from angle grinders are lighter, more compact and transportable than those with a separate drive.
Inexpensive angle grinders are not equipped with speed controllers, but a regular speed controller for a drill is suitable for them (no more than $20; usually $5 - $6). A “frequency generator” for an asynchronous motor up to 2.5 kW costs from $50.

About speed control

Why adjust the disk speed? In order not to exceed the maximum linear speed of the edge and/or rotation speed indicated on it. Otherwise, the disc may not rupture, but its performance will drop significantly, wear will increase, and the quality of the cut will deteriorate. The nominal rotation speeds of asynchronous motors 2800-2850 rpm allow the use of conventional disks with a diameter of up to 350-400 mm or more, which gives a cutting depth of at least 150 mm. The grinder spindle rotates much faster (from 6000 rpm), and placing a regular disk with a diameter of more than 160 mm on it is dangerous. The cutting depth reaches 50-60 mm, and the high-speed disc is expensive and wears out quickly. Installing a speed controller solves the problem. Productivity and cut quality do not suffer, because determined by the linear speed of rotation along the cutting edge.

About the name

An angle grinder sounds “technically”, but in fact it is inaccurate, because... The grinder does a lot more cutting than grinding. The “angle drill” is even worse, because... to drill – to drill, bore, for which an angle grinder is generally unsuitable. An angle grinder is a tracing paper from English. "angle grinder machine". But the English word to grind is much broader in meaning than all types of abrasive processing. For example, a meat grinder is a meat grinder. “To grind” does not have an exact Russian analogue; in meaning it is something like “shred into shreds along the back streets.” In general, the colloquial “Bulgarian” is terminologically incorrect, but it is short enough and it is clear what it is.