Getting full use of flap discs

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How does everyone use the full amount of a flap disc? It seems like I have to leave about 30-50% of the flap disc unsued since I cannot get close to the metal with the center of the disc with the guard on the angle grinder.Understanding in advance that the guards need to be left on an angle grinder for safety, is it OK to take the guard off when using a flap disc?Thanks in advance Jay.
Reply:I have a HF cheapie that I've used for years just for flap discs - and yes, I've taken the guard off.  It's probably not the safest thing to do, and others will tell you not to, but I've never had a problem.  Never grinding though...and never without full face protection.Miller Dynasty 200DXMillermatic 210 w/ Spoolmate 3035Hypertherm Powermax 380JD Squared Model 32Multiple fabrication tools & equipmentFull Powder Coating Setup
Reply:They don't work very well when they get down to 30% or so. Takes so long to remove material/polish that it is wearing out your grinder prematurely.Millermatic 200Hobart Handler 120Victor O/A & Ramco BandsawLincoln 225 ACSnapOn AD HoodMiller XMT304/22AHypertherm Powermax 1650 G3Lincoln Idealarc DC600 w/Extreme 12 VSMiller Digital Elite "Joker"
Reply:I have separate die grinders for metal cutting with the guard on to porting and flap disc, stones, etc. with no shield. Always wear safety glasses, flap discs coming apart don't hurt, a cuttoff wheel does.
Reply:I have a friend that builds custom cars and he had a flap fracture and run up his face. It didn't do any damage ( no more ugly than before). It was his warning and I told him so. Yes we gave him grief and also told him to change his ways. SO your call sport. Me not to be removed and eye protection.Miller thunderbolt 250Decastar 135ERecovering tool-o-holic ESAB OAI have been interested or involved in Electrical, Fire Alarm, Auto, Marine, Welding, Electronics ETC to name a just a few. So YES you can own too many tools.
Reply:I always wear eye protection and generally a flip down full face mask. Sounds like a flap disc will come apart just like a grinding disc, so I wiull keep the guard on.Thanks for the answers.
Reply:There's a couple of different face shapes of flap discs that seem to run standard across brands, type 27 and type 29. Play around with with one each and see if you get more mileage out of one than the other. Every body has their own way of holding & using these things and types of work they mainline on so it can make a small difference. Mostly I just run 'em till they quit doing what I want them to do then can 'em."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:use a standard grinding wheel in a bench vise or clamped to the table with vice grips , turn your grinder on and sand the edge off the flap disc cleans it up to new material so u can get the full potential of the disc, after u food grade day in and day out @ 5.01 each wheel u learn to use them to their fullest potential hope this helps.I forgot how to change this.
Reply:.....use a standard grinding wheel in a bench vise or clamped to the table with vice grips....
Reply:I go through a couple flapper disks a day at work in our industrial fab shop. all the guys that work there including me take our grinder with the worn down disk over to a belt sander. turn on ur grinder and turn on the sander and run the edge of the disk against the sanding belt for a couple second to wear it back down to a usable section. we do this at work and get use out of 85% of the disk before we grab a new one. wear ur face shield itll work out fine.
Reply:Throw it out and get a new one, how much are you really saving??????Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:alot.I forgot how to change this.
Reply:For grinding I use type 27 and flap disc type 29.Type 29 will help keep the nut and guard up and out of the way.If I understand the OP question.Here's pic...here.Edit: I just looked, mine thread on also, so there's no nut to get in the way.Last edited by skelley521; 09-17-2011 at 09:35 PM.Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:CGW site....here.Made in the U.S.A. Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:Learn to weld better - you won't need to grind so much.ɹǝʌo ǝɯ lloɹ 'sıɥʇ pɐǝɹ uɐɔ noʎ ɟı
Reply:Originally Posted by TozziWeldingThrow it out and get a new one, how much are you really saving??????
Reply:Who's grinding welds? I thought we were talking about metal preparation Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:Originally Posted by WeldingMachineX2Using abrasives to the stump will cost you more than save.
Reply:Originally Posted by TSORLearn to weld better - you won't need to grind so much.
Reply:Im not even sure if our grinders have guards. And if your flap disks are flying apart, you either need to stop buying wheels at harbor freight or learn how to grind.  I've never seen/heard of that happening, and I do quite a bit of finishing work.Have we all gone mad?
Reply:I just use flap discs to clean material since I buy most of my metal at the scrap yard.I am working on learning to weld better, kind or a slow process, but working on it.