What thickness cutoff wheel is best to use on a 4" angle grinder for cutting sheet metal (floors and 1/4 panels)? How much, if any, rookie abuse will the wheel withstand? Did a tech search and didn't find anything related to thickness of the wheel. Thanks
The very thin (1mm) discs have just become very common in Australia and are very good. I used to search to find thin discs for my die grinder but now they're available everywhere for standard grinders. They are very accurate, you loose very little metal and they create very little heat. I don't care how much of a rookie you are, you don't abuse your cut off wheels! None of them withstand abuse and if you don't use them with the respect they deserve they will bite you. Safe cutting, Pete
What Pete said. Try McMaster Carr or MSC, we use the 1/32 gl*** reinforced wheels. WEAR WORK GLOVES ALWAYS, and Eye Protection and sleeves. The little fibergl*** boogers itch like a *****.
I like the type mcmaster car sells for angle grinders. Raised hub type 27, they are either .045, 3/32 or a 1/16" thick. I like the thinner ones as they don't have to burn as much material up to cut. The raised hub sets the wheel away from your fingers. Look at mcmaster.com part number 4535A62 - they are like 2.34 each and last for about an hours worth of cutting 1/8" and thinner stuff
I save all the worn out 1/8" wheels from my 7" grinder and use them on my 4" and 4 1/2" grinders. A few tips on saving your wheels... 1. Try to cut so the leading edge of the kerf you're making doesn't become a knife edge. That'll eat your wheels faster than anything. 2. Don't bury more wheel than you have to. Just let enough wheel hang through the metal to make the cut. This will eliminate bind, and you won't heat the glue that holds the wheel together... which will lead to premature wear. 3. Don't apply pressure. Let the wheel cut... that's it's job. Keep your RPMs up. 4. Steady your work. If it's vibrating all over, it'll destroy your wheel. 5. Keep them dry. I guess this should be rule #1, but not as far as cutting goes. JOE
A little note on grinder safety. This past Saturday I had finished welding my exhaust and was dressing some welds with an electric grinder. It was a 4" electric grinder with a thick rubber backer and a thin grinding disk mounted on it. While grinding with very low pressure the thick rubber backer exploded, hitting me in the hand. The impact to my hand cut it, and severely bruised it to the point I could hardly bend my fingers for a couple of days. The cut is in the center of my palm. They could not s***ch it due the area and the fact it was a little mangled. They got the bleeding to stop cleaned it out and closed it with steri strips. It is healing OK just sore as hell. This could have been so much worse. I was not abusing it and the recomended speeds were not exceeded, I have no clue why it happened. You can never be too safe with these tools, and I will forever be more aware of where everyone else is in the garage when using them. Just a good reminder to be careful. As for cut off wheel thickness, I think the thinner the better. They seem to cut faster with less heat. As already posted, wear your gl***es and gloves.
I've gotta agree with Junkyard Dog 32. Using a lighter touch works much better. Your initial tendency is to want to push or pull it through, but you'll be much happier letting the tool do the work.
This reminds me... (not that it's the same thing)... NEVER use a cut-off wheel as you would a grinding disk or a stone. They aren't made for it, and WILL break apart. I keep a seperate 4 1/2" grinder with a stone on it, so I don't have to switch, back and forth. JOE
1mm cutting discs are exellent for cutting sheetmetal for bodywork,but try to use thicker disc for rougher sizes steel. The thin ones can easily bind,and break in a zillion pieces... Try not to remove the safety shield,if its equipped with one. Its better to just trim it,cut the corners off,and you can still use it on the narrow places,and be kinda safe. And always play Ministry's "Psalm 69" as loud as you can while cutting.
Harbor Freight has a package of 10 1/16" cut-off wheels for $6.99. I've been using them and they have performed quite well. Item no.45430-0VGA
I always use a face shield (along with safety gl***es) when using a cutoff wheel. The face shields **** to use in the heat of the summer but its alot safer. My brother had a cutoff wheel ****ter on him and it knocked out a tooth or two and left him with one hell of a scar.
I have also had a plastic backing pad explode a couple weeks ago while grinding some brackets I made clamped to my welding table. Pieces flew EVERWHERE across my shop, and two chunks buried their tips in my belly. Not a real pleasant experience, coulda been worse. Another tip on using the cutting wheels: Once you get a cut going, keep the angle of the wheel at a 90 degree angle to the work, don't wobble the grinder all over. If you do the wheel will **** in the hole and explode(no puns intended) Used carefully with gloves, face & eye protection they work great though-good luck
This is exactly how I chipped my cutoff wheel over the weekend. I realized I needed to re-clamp the metal as soon as I touched the wheel to it. Between the end of that thought and releasing the grinder switch, the cutoff wheel was ruined. So to answer your question, they won't take much abuse at all. I was just glad it didn't shatter.
What everyone else said SAFETY. I use the cheap harbor freight ones, and they work fine. Another tip is to cut in the proper direction that works with the rotation of the grinder. I didn't explain that very well but you'll see what I'm talkin about.
Thanks a bunch, JY Dog, I always wondered why some discs lasted longer than other ones, and its because the way I was grinding!
Thanks for all the input! I'm convinced to get a face shield and was already using gloves and long sleeves when using a wire cup wheel on it. Had some first hand experience with the trouble that can be had with the grinder.
I have a 3" air cutoff tool and a 4 1/2" electric. I buy Chinese discs in bulk, 50 to a box and they cost under 20 cents each. Sounds like HF is ripping folks off. I do a lot of cutting, from sheet metal to frames, rusty bolts, etc. Never had one come apart. And as everyone else has said SAFETY is paramount. And never ever overstress any cutting tool.
Damb!! Ministry is the best...Gets me a little too nuts though. I've been trying to find the old t-shirt with the 440 on the front and"NO MAN WITH A GOOD CAR NEEDS TO BE JUSTIFIED" on the back. Seriously, I use Blue Point cutting discs at work, they seem to last a long time.
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