Do-It-Yourself Bench Grinder: Converting a hand held grinder
There was a time when my handheld dremel tool was all I needed for grinding and metal cutting.  I reached a point, however, where my humble dremel just wasn't cutting it (no pun intended).  The bolts I needed to cut were getting larger and larger and my grinding needs were just... well... grinding on my poor dremel.   I decided to invest in a more industrial size grinder, and then adapt it for my projects which were, relative to the grinder's normal usage, fairly small.  Here you can see my new DeWalt brand grinder, model D28110.  This grinder has turned out to be the perfect additional to my small garage-shop.   To make it ideal however, I needed to be able to operate it 'hands free'
Before we begin
The manufacturer really did not intend for the grinder to be used this way, so if you decide to try this out then you do so at your own risk.  Grinders spin at amazingly high speeds and can make quick work of knuckles, fingernails and even tendons, especially when a cutting wheel is mounted.
In order to adapt the grinder for benchtop use I had to find a way to mount the grinder securely to the table top.  Fortunately the Dewalt D28110 was very well suited for this purpose.  On the top of the silver housing near the power switch you can see the threaded whole where the handle normally mounts.  There is an identical hole on the opposite side, and this is how the grinder is attached to the table.  It should also be obvious from the pictures that I had to cut a slot in my table to accommodate the wheel.  The slot is sized to accept a standard grinding wheel as well as the cutting wheel shown here.


From the underside of the table you can see the bolt used to mount the grinder.  A number of washers are used as spacers so that the bolt did not bottom out in the socket on the grinder
After mounting the grinder, a shoebox-sized plastic bin is mounted to the underside of the table.  The bin captures all of the fine metal dust generated when grinding and cutting. It is attached in a way that it can be easily removed for cleaning.
Another view of the mounted grinder.  The included  shield was loosened and rotated until it touched the table at the 'back' side of the wheel.  In this manner I am exposed to only a small slice of the wheel edge (especially important when the cutting wheel is attached)