No Weld Belt Grinder Build

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I am building one of the "No Weld Belt Grinders" from plans on Ebay - the plan set is superb FWIW.  It requires two idler wheels.  I can buy them or as I have been thinking, I can make them.  I am a novice on the metal lathe with lots of experience in a wood lathe and working with machinists in an aerospace repair shop.  Can anyone help me out with the steps to build one of these wheels, probably in the 3" range.  Probably aluminum would be the best material obviously with a bushing (steel, brass?) to run on.Also I will need a slotted drive shaft for the drive pulley.  Better to buy one or make one with a slot cutter?I am open to and will be grateful for any and all suggestions. Steve
Reply:I saw in the new Grizzly catalog some slotted drive shafting in various sizes.  I also have a set of plans from Michael Clerc for a "no weld" belt grinder.  It looks much nicer than the original "no weld" grinder plans.  Idler wheels, may be able to use a set of poly casters that you can grease from Grizzly also.  I'm going to plan on using a couple of those & make the drive wheel from aluminum.  If the poly caster wheels work, I'll get an 8" poly caster to use as a larger wheel.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:"No Weld" on a welding forum?  Where's the fun in that!StephenMillermatic 251Miller Syncrowave 200Miller 30A SpoolgunHypertherm Powermax 30Etc., etc., etc.............Cancer Sucks!
Reply:Look at Post #8And the ultimate KMG belt grinder accessoryThe KMG belt grinder can be welded together, however it looks pretty good just put together as designed.  Countersunk bolts, cold rolled steel......... MMMMMMMMMMM purdy!MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by 7A749Hey, stevewm.I have a couple of new Rockwell contact wheels 6" X 3" rubber surfaced.Interested?
Reply:Originally Posted by goinssr"No Weld" on a welding forum?  Where's the fun in that!
Reply:Originally Posted by stevewmDidn't say I wasn't going to weld it together instead of bolting it!
Reply:Hi SteveHi you thought about casting your own aluminum wheels?There are many sites dealing with aluminum casting.  Attached is a picture of a belt sander/grinder I built years ago. I cast the wheels and bearing housings for it.Also attached it a video about using a metal lathe to cut keyways in shafts.These will help you to expand your metal lathe experience.Have funTom [ame]http://www.youtube.com/watch?v=eVgZol6Mfvo[/ame]http://www.backyardmetalcasting.com/forums/ Attached Images
Reply:Wow, it's loud it here. Too much shouting. Just kidding. Someone posted this link a while back:http://www.surpluscenter.com/They seem to have lots of misc parts. You may find everything you need it there.kidtigger24  They think I’m crazy, but I know better. It is not I who am crazy. It is I who am MAD!