Make your cutoff wheels last 10x longer.

cdnpont · Canadian Poncho Superstar!

Make your cutoff wheels last 10x longer.

jmont64 · Canadian Poncho Superstar!

Well a couple of things. I don't know where he is buying his discs and I realize they are German but man I don't pay much for my discs and most of the time I am using the thin ones. I usually use the score method but for me it is easier to keep a straight line when I am headed across the sheet as I score aways and then back and then continue a little further and then back and so on. Also most of the time I cut going against the rotation of the blade. To me it looked like he was cutting with it. By going against it the blade doesn't get drawn in and break off those chunks. By no means an expert like you guys but my practice of cutting plywood all my life does allow me to make some decently straight metal cuts.

cdnpont · Canadian Poncho Superstar!

If at all possible, I try to use the score method nowadays. I've had too many scary kickbacks (and have been pretty lucky) with jammed and shattered blades when plunging and having a bind.

Pontiacanada · A Poncho Legend!

I use angle grinder cut-off wheels at least once a week as a hobby. I use both techniques depending on the material.

Material hardness and type will affect cut-off wheel longevity, also, how you have your work secured and your grip on the grinder.

Buy name-brand angle grinders with a high amperage rating. They cut better (just as high amp wood-working tools do). I own (5) different angle grinders (Mikitas and DeWalts), and have them set up for different tasks (cut-offs, flap discs, grinding wheels).

I buy cheap discs on sale at Crappy Tire/Princess Auto for everyday jobs, but the disc manufacturer DOES make a difference in wear. Name brands DO last longer and cut better.

The angle grinder is my #1 tool by far!

I even have a vintage Sears "hog of a grinder" that I converted into a bench sander (pictures to follow). You might have laugh after seeing it.

Canadian Poncho · A Poncho Legend!

I've cut a lot of steel this summer working on the truck. The scoring method works best. If I do a plunge cut I apply very little pressure and can "feel" when the metal gets hot enough from the friction of the disc that it almost feels like it's melting. At that point I apply a bit more pressure and the disc cuts through the steel like butter.
Somewhat related- When grinding welds forget about a grinding disc. Get those flapper discs (Canadian Tire often puts them on sale) I have both 80 and 40 grit flappers. The 40 grit are great for grinding welds and last quite a while.

cdnpont · Canadian Poncho Superstar!

I think that is the key to the scoring method on thin Todd, it's actually more or less melting the metal out with friction rather than chipping it out with the plunge.

On thick material I think you obviously need to plunge, otherwise you'll be all day. But in effect, your more or less melting it out of the way as you go. And it is true, if the material is flimsy, it seems to tear up the discs from the side due to vibration. Securing it is also key.

Pontiacanada · A Poncho Legend!

Pontiacanada wrote:
I own (5) different angle grinders (Mikitas and DeWalts), and have them set up for different tasks (cut-offs, flap discs, grinding wheels).
I even have a vintage Sears "hog of a grinder" that I converted into a bench sander (pictures to follow). You might have laugh after seeing it.

Grind, flapper and cut-off dedicated grinders:

The "hog". Your arms get tired with this one. That's why I converted it to a bench top sander:

4SPEED427 · A Poncho Legend!

Wow, the shields are still on. I have no patience for shields, they always come off.

Pontiacanada · A Poncho Legend!

4SPEED427 wrote:
Wow, the shields are still on. I have no patience for shields, they always come off.

I modified the flapper disc one (the small Mikita), by cutting off the shield "lip" in front of the disc.

The other Mikita's shield doesn't get in the way at all while grinding, and the Dewalt ratchets automatically to any angle when cutting, and is no problem. The Dewalt is a torquey sweet machine (11 amps - 11,000 rpm.)

The shields do direct some sparks away, but I also wear a leather apron.

cdnpont · Canadian Poncho Superstar!

Yea, I'm guilty of losing the shields as well. I should know better.

I have the same Makita 9005B Darryl.

jmont64 · Canadian Poncho Superstar!

Great tools. I don't have the arsenal like you Darryl but usually just keep a couple going, one with the flapper and the other as a cutter. Have kept my guards on as they are quite versatile. Mostly use my 60v DeWalt because of the flexibility especially under a vehicle.

Pontiacanada · A Poncho Legend!

cdnpont wrote:
Yea, I'm guilty of losing the shields as well. I should know better.
I have the same Makita 9005B Darryl.

I pulled that Mikita out of our Waste Watch (dump), nothing wrong with it, works great as a grinder!

I have extra shields ... that's where your's and Carl's went. wink

Pontiacanada · A Poncho Legend!

jmont64 wrote:
Great tools. I don't have the arsenal like you Darryl but usually just keep a couple going, one with the flapper and the other as a cutter. Have kept my guards on as they are quite versatile. Mostly use my 60v DeWalt because of the flexibility especially under a vehicle.

There have been a couple times I could have used a battery grinder.

I also have an extra, new DeWalt corded. Just in case. smile (and I have a Bosch that I picked up cheap ... I never use it and might resell it).

I find the Dewalt a better machine design-wise.