NSI Solutions SinkBULLIT SB-KIT2 User manual

nsisolutions.com English Rev -
with Rapid Z™-CUT & Rapid Z™-DRUM
INSTRUCTION MANUAL
SB-KIT2
Please read this instruction manual thoroughly to ensure the safe and correct use of this tool. Keep this
manual in a place where operators can access it anytime necessary.
INTRODUCTION
Thank you for purchasing the NSI Solutions Sink BULL™LT.The Sink BULL™LT is a machine specifically
designed to grind perfect repeatable cutouts for undermount sinks in stone and quartz slabs. Please
read this instruction manual thoroughly for assembly instructions, safe operation, tool handling, tool
capability information, and all other precautions before using the tool. Keep this manual in a place
where operators can access it easily.
To be used, the Sink BULL™LT is assembled to an angle grinder and has grinding tools installed.
Observe all operational and safety instructions contained in the instruction manual supplied with the
angle grinder and the associated Rapid Z™-CUT and Rapid Z™-DRUM grinding wheels.
Visit nsisolutions.com for resources and videos featuring the Sink BULL™LT
or
visit NSITools on YouTube
Proudly Designed & Assembled in the U.S.A. from Global Components

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TABLE OF CONTENTS
INTRODUCTION.............................................................................................................................................1
TABLE OF CONTENTS.....................................................................................................................................2
GENERAL SAFETY WARNINGS .......................................................................................................................3
ASSEMBLY INSTRUCTIONS ............................................................................................................................4
Sink BULL™LT Package and Accessories....................................................................................................4
Tools Needed for Assembly ......................................................................................................................5
Prepare Grinder ........................................................................................................................................5
Install Grinder into Carriage......................................................................................................................6
Install Carriage and Handles .....................................................................................................................8
Final Assembly ..........................................................................................................................................9
USE INSTRUCTIONS.....................................................................................................................................11
Before Using the Sink BULL™LT...............................................................................................................11
How to Operate ......................................................................................................................................12
Overview.................................................................................................................................................12
Grinding Wheel Selection .......................................................................................................................12
Rough Cut the Hole.................................................................................................................................14
Setup the Sink BULL™LT ..........................................................................................................................14
Clamp the Template in Place ..................................................................................................................14
Set the Initial Grinding Height.................................................................................................................15
Initial Grinding/Shaping ..........................................................................................................................16
Final Grinding/Shaping............................................................................................................................17
After Use .................................................................................................................................................18
CLEANING AND MAINTENANCE..................................................................................................................18
CONTACT NSI SOLUTIONS...........................................................................................................................19

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GENERAL SAFETY WARNINGS
Read and Understand All Instructions
Failure to follow all instructions listed below may result in electric shock, fire and/or serious
personal injury.
Use Proper Safety Gear
Always wear eye protection and proper personal safety equipment when using this product.
Observe Maximum RPM
Maximum 8500 RPM for Rapid Z™-DRUM wheels and 12000 RPM for Rapid Z™-CUT wheels.
Caution
Firmly attach all components before use.
Wet Use Only
Rapid Z™ grinding wheels and drums are designed for wet use only.
Caution
Observe all safety instructions provided with the electric grinder and all associated tools and
accessories.
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ASSEMBLY INSTRUCTIONS
Sink BULL™LT Package and Accessories
Included with Sink BULL™LT
Purchased
separately
MAIN BOX
(1) Sink BULL™LT base assembly
●
(1) 3” Rapid Z™-CUT- Grinding wheel with template bearing
●
(1) 3” Rapid Z™-Drum - COARSE grinding drum with template
bearing
●
(1) 3” Rapid Z™-Drum- FINE grinding drum with template bearing
●
(1) Custom multi-function wrench
●
(1) Sink BULL™LT Instruction Manual
●
BOX LABELED CARRIAGE (located inside main box)
(1) Carriage
●
(1) Height adjustment handle
●
(1) 5/8” square head bolt
●
(1) Bolt head spacer
●
(1) 5/8” washer
●
BOX LABELED HANDLES, HARDWARE AND ACCESSORIES (located inside
main box)
(2) Handle Assemblies
●
(1) Splash guard angle
●
(2) 14mm hex head bolts
●
(2) 14mm x 28mm washers
●
(1) 14mm x 24mm washer - Zinc
●
(4) 6mm socket head cap screws
●
(2) 6mm washers
●
(1) Angel Guard Products –Cord Connect
●
(1) GFCI adapter
●
ALSO REQUIRED
(1) Makita GA7021, 7” angle grinder
●
(1) Accessory grip handle (included with Makita grinder)
●
OPTIONAL ACCESSORIES
1” Rapid Z™-DRUM - COARSE grinding drum with template
bearing
●
1” Rapid Z™-DRUM - FINE grinding drum with template
bearing
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Tools Needed for Assembly
•22mm Open End Wrench or Crescent Wrench
•5 mm Allen (Hex) Wrench
•1/8” Allen (Hex) Wrench
Caution
Always be sure that the grinder is switched off and unplugged before performing any work on the
tool.
Prepare Grinder
1. A Makita grinder, model number GA7021, must be purchased separately for use with
the Sink BULL™LT.
2. If installed, remove the wheel guard from grinder (see Figure 1). The Guard will not be
required for use with the Sink BULL™LT.
3. If installed, remove the grip handle from grinder (see Figure 1). Save the handle to
reinstall on the Sink BULL™LT in a later step.
4. Using a 5mm Allen or hex wrench, remove quantity (4) socket head cap screws from the
head of grinder at locations shown (see Figure 2). Do not remove the grinder head.
Save the screws to reassemble the grinder if it is removed from the Sink BULL™LT
FIGURE 1 –Prepare Grinder FIGURE 2 –Remove Screws
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Install Grinder into Carriage
5. Insert the Bolt Head Spacer and the 5/8” square head bolt into the carriage with the
head nested in the recess (see Figure 3).
FIGURE 3 –Insert Spacer and 5/8” Bolt
6. With the spacer and 5/8” bolt inserted into the carriage, place the carriage over the
head of the grinder (see Figure 4).
7. Using a 5mm Allen or hex wrench, install quantity (2) of the supplied 6mm socket head
cap screws through the splash guard angle, and through the carriage holes closest to the
grinder body and thread them into the grinder head holes exposed in step 4 above (see
Figure 4). Do not tighten until all screws and bolts have been started.
8. Using a 5mm Allen or hex wrench, install quantity (2) of the supplied 6mm socket head
cap screws and 6mm washers through the remaining carriage holes and thread them
into the remaining grinder head holes exposed in step 4 above (see Figure 4). Do not
tighten until all screws and bolts have been started.

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9. Using a 22mm open end wrench or Crescent wrench, install quantity (1) 14mm hex head
bolt and 14mm x 28mm washer through the large holes on the side of the carriage and
into the threaded holes on the side of the grinder head. Install these bolts on both sides
of the carriage. Do not tighten until all screws and bolts have been started.
10. Tighten all screws and bolts.
FIGURE 4 –Install Grinder into Carriage

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Install Carriage and Handles
11. Place the “V” nose of the carriage assembly (with the grinder installed) into the” V”
notch of the base assembly with the 5/8” bolt protruding through the slot (see Figure 5).
12. Place the 5/8” washer over the bolt and install the height adjustment handle by hand
tightening it onto the 5/8” bolt (see Figure 5).
13. Note –the height adjustment handle can be adjusted to many different positions by
pulling the handle straight out after it is tightened and rotating to the desired position.
14. Insert and hand tighten the handle assemblies into place on each side of the
Sink BULL™LT as shown (see Figure 5).
FIGURE 5 –Install Carriage and Handles

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Final Assembly
15. On the Sink BULL™LT base assembly, on the end opposite the height adjustment
handle, use a 1/8” Allen or hex wrench to remove (2) #10-24 screws attaching the red
hose/cord clamp. Press the grinder cord into the clamp and reinstall the screws (see
Figure 6). Make sure the spiral wrapped water hose is still clamped and take care to not
overtighten the screws
16. Install the accessory grip handle that came with the Makita grinder with (1)
14mm x 24mm washer into the threaded hole provided (see Figure 6).
FIGURE 6 –Final Assembly

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17. NSI Solutions LLC has provided an Angel Guard Products - Cord Connect with the
Sink BULL™LT kit. When using an extension cord with the grinder, install the Cord
Connect and gasket per the manufacturer’s instructions to help keep water out of the
electrical connection (see Figure 7).
FIGURE 7 –Angel Guard –Cord Connect
Caution
Ensure the Angel Guard - Cord Connect remains on the grinder/extension cord connection at all
times.
18. NSI Solutions LLC has provided a GFCI adapter with the Sink BULL™LT kit. Ensure the
grinder or extension cord is plugged into this GFCI adapter or other GFCI protected
circuit when in use (see Figure 8).
FIGURE 8 –GFCI Adapter
Caution
Ensure GFCI remains connected to grinder at all times when in use or that the grinder is plugged into
other GFCI protected circuit.
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USE INSTRUCTIONS
Before Using the Sink BULL™LT
Before using the assembled Sink BULL™LT be sure to complete the following preparations.
Supply the Specified Voltage
Supply the voltage specified on the nameplate of the grinder. Otherwise damage could result to the
machine, or increase the risk of personal injury.
Install a Ground Fault Circuit Interrupter (GFCI)
To prevent electrical shocks, be sure that the power circuit being used is protected by a GFCI device
or be sure to install the supplied ground fault circuit interrupter (GFCI) between the main power
supply and the cord of the machine.
Keep Water Out of the Grinder
Do not let water into the motor of the electric grinder. Water inside the machine will weaken the
electrical insulation of the motor and may result in electric shock. Ensure the splash guard angle is
installed at all times during use (see Figure 4).
Organize the Work Area for Safe Operation
Before beginning operations, make sure that the work area is well organized for safe operation of
the Sink BULL™LT.
Use Proper Safety Gear
To prevent damage to eyes from flying debris, wear protective glasses or face shield. Be sure to
wear waterproof safety boots, appropriate hearing protection and dust protection as required.
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How to Operate
Overview
1. Creating a perfect cutout for an undermount sink is a multi-step process. The
Sink BULL™LT helps simplify this process and reduces the skill level required to quickly
achieve excellent results.
2. Follow these basic steps to produce the perfect sink cutout:
a. Drop the center of the sink hole with an appropriate saw.
b. Rough grind the hole to shape with the Sink BULL™LT and the Rapid Z™-CUT
grinding wheel utilizing a simple, inexpensive, shop made template.
c. With the template still clamped in place, clean up the hole with the
Sink BULL™LT and the COARSE Rapid Z™-DRUM or other vacuum brazed drum
wheel.
d. With the template still clamped in place, finish smoothing the hole with the
Sink BULL™LT and the FINE Rapid Z™-DRUM.
e. Remove the template and polish the edges of the cutout.
Grinding Wheel Selection
3. For the first rough grinding step (step b. above) we supply our Rapid Z™-CUT - a 3”
stacked blade “Z” wheel. This grinding wheel has 12 stacked diamond blades, and a
bearing mounted stainless ring to ride against the template. It was specifically designed
for use with the Sink BULL™LT. The blades grind quickly and can be rearranged easily
to correct “apple coring” for maximum blade life. When they are completely worn out,
the blades are inexpensive to replace. The template follower ring incorporates a two
stage design to help compensate for blade wear (see Figure 9). Other grinding wheels
may be used but have not been tested by NSI Solutions LLC.
4. For the second and third grinding step (step c. and d. above) we supply our
Rapid Z™-DRUMS –two 3” Vacuum brazed drum wheels (COARSE grit and FINE grit)
with top mounted bearings to ride against the template. This 3” diameter version will
accomplish most work, but a 1” diameter version will be required for tight corners and
are available for purchase separately. The Rapid Z™-DRUMS are sized to work in
sequence with the Rapid Z™-CUT. Each will leave a small amount of material to be
removed with the next tool. The FINE grit drum produces a ready to polish surface flush
to the template. The 3” Rapid Z™-DRUMS are reversible to extend tool life and when
completely dull the drum portion is inexpensive to replace. Additionally, the height of
all Rapid Z™ products have been matched so that height adjustment between grinding
tools is not required.

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FIGURE 9 –Rapid Z™-CUT and Rapid Z™-DRUM by NSI Solutions LLC

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Rough Cut the Hole
5. Set your work piece on the work bench and secure it using appropriate clamps if
required.
6. Using your template, trace the sink profile onto the stone at the correct location.
7. Remove the bulk of the sink cutout with a saw and appropriate blade as close to the line
as feasible. Multiple types of saws can be used depending on the size and shape of the
sink cutout. A Small, water feed, circular saw, a bridge saw/core bit combination, or a
blade mounted on an angle grinder are popular options.
8. Take precautions to support the cutout so it does not drop when the cut is complete.
Setup the Sink BULL™LT
9. Install the Rapid Z™-CUT grinding wheel or other appropriate initial grinding wheel
onto the Sink BULL™LT. The grinder has an arbor lock to aid installation and removal
of the grinding wheel.
10. Connect the Sink BULL™LT to a garden hose. Make sure the valve on the
Sink BULL™LT is off and turn the water on at the hose bib.
11. Plug the Sink BULL™LT into a GFCI protected outlet or use the GFCI adapter provided.
Caution
Follow all instructions and safety precautions provided with the Rapid Z™-CUT and Rapid Z™-DRUM
and follow all manufacturer’s instructions and safety precautions for any other grinding wheels used.
Caution
Ensure grinder remains connected to a GFCI protected outlet at all times when in use.
Clamp the Template in Place
12. Place the template over the rough cutout and align it to the previously traced line.
13. Clamp the template in place with C-clamps. Two clamps are usually sufficient. Place the
clamps at the corners of the template.
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Set the Initial Grinding Height
14. Use the wrench handle as a height gauge to set the initial grinding position. There are
two locations on the wrench handle corresponding to template thickness (see
Figure 10). Determine which position most closely matches your template thickness.
15. With the carriage clamped high, insert the wrench handle between the carriage and the
base plate at the position matching your template thickness. Loosen the height
adjustment handle and lower the carriage to rest on the wrench handle. Tighten the
height adjustment lever (see Figure 11).
16. Remove the wrench.
NOTE: This is an initial height setting and may need to be adjusted further. Template
material and thickness varies considerably. This method will give you a rough starting
point. You can always modify your wrench handle as required to match your specific
templates or cut a custom height gauge block from wood
FIGURE 10 –Wrench Features

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FIGURE 11 –Use Wrench as Height Adjustment Gauge
Initial Grinding/Shaping
17. Place the Sink BULL™LT onto the template, spanning the hole, with the Rapid Z™-CUT
grinding wheel inside the hole.
18. Check the height of the grinding wheel. If required adjust the height of the grinder until
the bearing is riding on the template and the grinding wheel is removing the stone (see
Figure 12). Mark the final height of the carriage on the inside of the V-Rail for future
reference.
19. Turn on the water valve and adjust the nozzle to spray a sufficient fan of water onto the
side of the grinding wheel. Ensure plenty of water is used. If you are creating dust
during grinding, then more water is required.
20. Start the grinder and lock the switch in the ON position.
21. Pull the Sink BULL™LT into the template until the bearing is riding against the template
and work the Sink BULL™LT back and forth grinding the cutout to the shape of the
template. This is accomplished when the bearing is riding on the template and no more
stone is being removed. Work the Sink BULL™LT back and forth until the cutout is
ground halfway around. The Rapid Z™-CUT will leave a small amount of material for
removal with the COARSE Rapid Z™-DRUM.
22. Turn off the power and the water.

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23. Pick up the Sink BULL™LT and lift it over the C-clamps to the opposite side of the
cutout.
24. Complete the rough grinding of the remaining half of the cutout moving the C-clamps to
new locations if required.
25. Turn off the power and the water.
FIGURE 12 –Adjust Grinding Wheel Height so Bearing Rides on Template
Final Grinding/Shaping
26. Unplug the grinder from the power supply.
27. Replace the Rapid Z™-CUT with the COARSE Rapid Z™-DRUM or other vacuum brazed
drum wheel (approximately 40 grit). The supplied wrench can be used to loosen the
Rapid Z™-CUT for replacement.
28. Plug the grinder back into a GFCI protected power supply and repeat steps 17 through
26 above. The COARSE Rapid Z™-DRUM will leave approximately .020” (.5mm) of
material proud of the template. The cutout could be polished after this step but
cleaning it up further with a fine drum will yield an easier to polish edge.
29. Replace the COARSE Rapid Z™-DRUM with a FINE Rapid Z™-DRUM (approximately 120
grit).
30. Plug the grinder back into a GFCI protected power supply and repeat steps 17 through
26 above except the FINE Rapid Z™-DRUM will leave the edge of the cutout flush with
the template and smooth enough for easy polishing.
31. After all grinding is complete; remove the Sink BULL™LT and template. The cutout is
ready to polish.

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After Use
32. Clean and dry the electric grinder as noted in the Cleaning and Maintenance section.
CLEANING AND MAINTENANCE
Caution
Always be sure that the tool is switched off and unplugged before attempting to perform inspection
or maintenance.
Caution
The grinder air vents need to be kept clean. Regularly clean the grinder air vents or clean the vents
whenever they start to become obstructed.
Caution
To maintain product SAFETY and RELIABILITY, repairs to the grinder should be done by an Authorized
or Factory Service Center.
The following procedure will extend the longevity of your Sink BULL™LT and Rapid Z™ components
1. Blow out the electric grinder vents after each use using a dry air supply to remove any dust and
moisture. This will extend the life of the electric motor.
2. Occasionally cleaning the height adjustment mechanism will keep it working easily and smoothly.
a. Remove the height adjustment handle and washer (see Figure 5).
b. Remove the carriage with grinder installed.
c. Wipe the “V” ways clean on both the carriage and the base assembly.
d. Wipe the threads of the 5/8” bolt clean.
e. Re-assemble (see Figure 5).
3. The ball bearings in the Rapid Z™ products will last longer if they are blown dry, with
compressed, air after each use and stored in a dry place.
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CONTACT NSI SOLUTIONS
If you need help locating replacement items or just have questions, feel free to contact us.
You can reach us at:
Web: nsisolutions.com
Email: [email protected]om
Phone: [phone]
Snail Mail: NSI Solutions LLC
13020 Mukilteo Speedway, Suite A
Lynnwood, WA 98087
Usage Tips: For usage help and/or tips visit nsisolutions.com or watch the videos on our
YouTube channel NSITools.