Drop saw converter for Angle Grinder

thingiverse

This is a tool to convert a hand angle grinder into a drop saw grinder. From personal experience, it works very well cutting smaller metal tubing, bar, and so on. With larger cuts, the metal must be rotated a few times to finish the cut. On very large pieces, the cuts will need to be finished by hand, but you'll have a great guide/starter cuts to follow thanks to the guides. Design: ======== This was designed to fit 10mm linear rods that I had laying around and bearings that fit those rods. If you have another size, you can adjust the file (or just purchase the 10mm rods). The FreeCAD files are included for any adjustments. Parts: -------- 1 piece of wood or similar to fit the base onto 2 x 10mm rods 4 x linear bearings to fit the rods 2 x M2 bolts to tighten the clamp at the back of the rails A large bolt to pass through the swivel clamps A lock nut to attach to the swivel clamp bolt A metal screw clamp to attach the grinder with Spare parts: -------- I've included some guides you can use/attach to the wooden board. This allows for accuracy in getting 90-degree and 45-degree cuts. Tips: ===== I wanted to spread the pressure on the main body where it attaches to the wood. You'll see in the usage photos I simply got some metal offcuts, cut them to size, and drilled some holes to match the base holes. This spreads the load brilliantly and stops too much pressure on the base itself. You could alternatively use large washers or similar. I never tried it without the metal, so it might even stand up okay without any support? Usage: ===== I found sliding the grinder in, gently tightening, and using a spirit level before final tightening gave me solid results in terms of accuracy. The 45-degree guide worked really well for making a bike rack where I had a lot of angles to cut and needed them accurately. This won't solve all your problems if you're doing a lot of larger work, but if you're doing smaller metal cuts, it will really hold its own. IMPORTANT: ===== The flying hot metal sparks WILL melt your PLA base. I simply placed a piece of L-shaped metal I had laying around in front of the base and it deflects the sparks and keeps it all working well. In time, I wonder if the guides might melt? If that happens, I'll make sure I cut some out of metal before they melt. Terms: ===== Share the design, change it, etc. No need to mention my work. It's for everyone to do anything with.