1x30 Variable Speed Grinder - Treadmill - WIP

[PoolQs]

Hello everyone !!
I have been making knives for approximately 18 months and produced 28 knives all on my
20 yr old Sears 1x30” 1/3hp sander. Like most new knife makers, we are on a VERY limited budget
and not all of us can afford that awesome KMG 2x72. For the last 4 months, I have been researching
on how to make my own 2x72. Watched many videos and read more forums that I care to
admit to. In many cases, I have seen these made from treadmills. Has everything you need;
bigger motor, bearings, variable speed, etc.

I have talked to many sources lately and have warned me about using a treadmill setup for my
2x72. The motors, bearings, and belts are all different. I was also told that since it was an
open motor, shaving and debris would ruin the motor quickly. OK, I believe all of that.

But because of all the research that I have done on this treadmill setup, I decided until I could
afford to build that 2x72, that I would soup up my 1x30 and make a variable speed unit so I
could slow everything down from my normal 3450rpms. (a finger and steel burning maching)

Everything I found and read was strictly about the 72 and not many modifications about 1x30.
Here is a WIP that I did to hopefully help the new makers out there, on a budget, make something
until they can move up to the bigger machines.

Here is my current setup that I have been using for all my knife making including handles:


I then went to craigslist and watch it for about a month looking for the best deal and the
biggest motor. This guy just wanted it out of his garage. He wanted $125 for a month and
no takers. I called him up and offered him $30 to haul it away. He accepted.
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Next thing I had to do is undo the tracking and pull out the long bearing units that the mat
ran on. Found out that the pulley system was totally different than I expected. Wasn't a flat
belt or a V. Opps... now what...hmmm. I tried to disassemble the bearing unit to get the pulley
off but somehow it was fixed to the long bearing bar. I waited awhile and disassembled the 1x30:
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I wasn't able to get the bearing unit off so I decided just how to get the pulley assemble off.
I was locked into the bearing and epoxied in. After some choice words, I was able to get it off.
It just left me with an 8 thread round rubber piece with a 2.5" hole in it. How was I going to
but that on a 13/32" shaft. I came up with this. I made a wood circle to act like the bearing
unit. I also added 2 pieces of aluminum rods into both to make sure that neither would spin
under pressure. All of it was epoxied together.

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After cleaning all that up and making sure it was true, I attached it to my grinder. I then pulled
the motor out and the control boards to see how I would line everything back up.

Next trick was how to bolt everything down and be able to make tension on the belt. I cut out
the motor housing out of the treadmill and used it as my anchor. I then cut out an angle
piece and attached it so I could thread bolts on top to adjust the belt pressure.

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I took the control box out of the treadmill and cut it down in size. Moved the solenoid and the
grounding wires and used my bandsaw to cut away the excess. I mounted it on the wall to
keep it out of the way and until I will build a new box for it.

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Now the final stage, the variable speed unit. I took the whole unit off the treadmill and hooked
everything back up just to make sure everything was still working. All good !! I knew that I
didn't want the "handlebars" and sure didn't need the heart monitor. I took them apart and then
cut away the excess of the panel to only the part that I wanted to use.

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I mounted it on the wall in front of me for easy access.

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Now to wire everything back together and make sure that it still fires up. Hopefully NOT go up in fire. It works !!

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Now for the maiden voyage, putting steel to it and really press down hard to see if everything
stays together and doesn't bog down.

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SPARKS !!! I could not bog it down with even 2 hands. That is hardened Aldo 1084 at 58rc.

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I turned down the rpms to low and tried some wood out. Oh my... no burning anymore wood !!

I really hope this helps out some new knife makes out there. This entire setup cost me $30
and used all bolts, iron, screws, etc from that one treadmill. As stated earlier, I will be making
a new box for the control panel and shield all the wiring. I have NO prior experience in electrical
or mechanical areas. This is all from a lot of reading and knife forums.
Thanks for reading my WIP and if anyone has further knowledge of areas I can improve on this,
I would love to hear them and incorporate them in this design.
Troy

 

[JawJacker]

First thing I would do is tape up that end of the grinder cord. Good job

 

[Bill Hubbell]

Good Job! It's amazing what a guy can do when you put your mind to it- and need to stay under budget!

 

[Justin Presson]

That's awesome man!

 

[John Wilson]

$50 Knife Shop, eat your heart out!

 

[N.N]

I've been using a 1x30 for years now with no real intention of getting anything bigger until I'm doing enough knives a year to warrant it, win the lotta, a rich uncle in didn't know about dies, and/or one magically appears at my house. Maybe the monkey's that flew outta my butt will return with one. I have neither the space, the time nor the willpower (reminds me of putting together furniture and table and kids toys that takes hours and loss of sanity) to try and build my own 2x72 anytime soon.

That's kinda neat! Simple and cheap too! I might have to think about looking into something like that. I've learned to work around the 1x30, the only thing that kills me is the speed and using higher grits and the lack of platten length.

 

[bladegrinder]

Awesome, I like the control board too. I found a treadmill on the side of the road and pulled the motor too but my plans are to make a generator windmill out of it. I have some land in the woods and have a big home made solar panel that keeps the battery in my trailer charged. if you chuck the shaft of that motor in a drill you'll see DC voltage coming from the input leads, I think the one I have was putting out around 30 volts.