I love finding new life in old metal. Instead of letting a worn-out bicycle rust away, I turned the frame and a few salvaged parts into a compact, sturdy angle grinder stand and multi-purpose workshop tool. It saves money, uses parts you already have, and gives you a versatile fixture for cutting, grinding, and polishing workpieces.
🛠️ What we’ll make and why
My goal was simple: build a reliable, safe fixture that holds an angle grinder in a repeatable position so I can use it like a mini chop saw, bench grinder, or sanding station. The bicycle frame provides a ready-made backbone, the wheel hub and fork make great pivot points, and a few plates and welds turn everything into a rigid tool.
🔧 Materials and tools you’ll need
- Old bicycle frame (any size will do, but a sturdy steel frame is best)
- Angle grinder (the tool the stand will hold)
- Metal plate stock for mounting brackets (6–10 mm recommended)
- Bolts, nuts, and a pivot bolt with locknut
- Wheel hub or fork piece for the pivot
- Welding equipment (MIG or stick works)
- Angle grinder discs appropriate for the task (cutoff wheels for cutting; grinding wheels for grinding; flap/wire wheels for finishing)
- Measuring tools, clamps, and a marker
- Personal protective equipment: welding helmet, gloves, eye and hearing protection
⚙️ Step-by-step build process
1. Strip the bicycle and plan the layout
I start by removing wheels, handlebars, seat, and components I don’t need. Leave the head tube, fork, and a section of the top tube and down tube—these become the frame for mounting. Lay out where the angle grinder will sit and how the pivot will work. Think about cutting clearance and handle movement so you can operate the trigger/lock and change discs without hitting frame tubing.
2. Fabricate the mounting plates
Cut two matching metal plates that will clamp the grinder to the frame and form the pivot bracket. Drill holes for the pivot bolt and for mounting to the bicycle frame. I use 6–10 mm plate to keep things rigid. Chamfer holes slightly to avoid sharp edges and to make bolting easier.
3. Build the pivot and attach the grinder
Repurpose the fork or wheel hub area to become the pivot point. Bolt the mounting plates together around the grinder body so the grinder becomes a removable cartridge. Install a pivot bolt through the fork and the bracket so the grinder can tilt like a small chop saw. Add washers or bushings to keep movement smooth but without wobble.
4. Weld and finish the assembly
Once the layout and fit are right, tack-weld the brackets and reinforcements, check alignment, then finish-weld. Grind welds smooth where necessary so nothing interferes with the grinder’s guard or handle. Add stop blocks so the grinder cannot pivot beyond the safe working angle and a locking bolt to secure the head when not in use.
5. Adjustments, safety guards, and final setup
Fit a guard between the tool and the workpiece to direct sparks and fragments away from your face. Check all fasteners, make sure the grinder guard is intact, and test the pivot action slowly. Balance and eliminate any play at the pivot—tiny movement turns into dangerous vibration at grinder speeds. Bolt or clamp the stand to the workbench to prevent tipping.
🔥 Practical use cases and tips
- Use for short repeatable cuts like trimming bolts, pipe ends, and small stock.
- Fit a wire wheel or flap disc for polishing and finishing. The fixed position makes light polishing work easier.
- Clamp the workpiece to a small fence or jig that you weld to the frame for repeatability.
- Orient the guard so it shields you while directing sparks away—never remove or defeat the guard.
⚠️ Safety rules I always follow
- Always wear eye protection, a welding helmet when welding, hearing protection, and gloves.
- Ensure the grinder’s guard is fitted and never use a disc that is cracked or past its expiration date. Confirm the wheel’s RPM rating meets or exceeds the grinder’s no-load speed.
- Balance the pivot and eliminate axial play. Even small vibration can quickly become unsafe.
- Disconnect power when adjusting or changing discs.
“Repurpose first, buy later”
❓FAQ
Can I build this without welding?
You can assemble a functional bracket system using heavy-duty bolts, clamps, and U-bolts instead of welding, but welding produces the most compact, rigid, and safe result. If you avoid welding, over-engineer the clamps and check everything frequently for loosening.
Will this work with any angle grinder size?
Most angle grinders will work, but the mounting bracket needs to match the body diameter and handle placement. Smaller grinders are easier to balance and produce less vibration. Make sure the disc size is appropriate for the clearance in your setup.
Is it safe to use a bicycle hub for the pivot?
Yes, a solid bicycle hub or fork section can be an excellent pivot because it was designed for rotating loads. Ensure bearings are in good condition or replace them with a simple bushing to handle the compressive loads of the pivot bolt, and consider dust shields or sealed bearings to cope with abrasive dust.
What are other uses for this bicycle-based fixture?
Besides cutting and grinding, you can convert it to a sanding station, a light polishing bench, or even a clamp-and-hold fixture for welding small pieces. The basic principle is a rigid frame plus a repeatable pivot and stop.
