"Jim Stewart" wrote in message
...
I've had one inch sparks from the belt
to my hands while using it. Any suggestions?
It's chassis is connected to the power
plug ground.

Get an ohmmeter and test the ground connection between the
chassis and the 3rd pin on the plug. Power cords have been known
to go bad. Less likely is a faulty ground at the outlet.
I assume you are not using a 2 wire extension cord - right?
Art