General Henry Shrapnel

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British General Henry Shrapnel is on my mind. Mainly because I have been picking pieces  of my latest wire cup out of my jeans for half an hour. What is with these new wire brushes that they dont last worth nothing. I like to Stick and Torch weld and am getting into FCAW. LONG AGO I gave up hand brushing welds as slow and annoying so I prefer to use my 4" grinder as a dedicated wire brush. The problem is that using a wire cup is the best for getting in small areas so I dont use a wheel. The cups I have been buying lately frankly SUCK. These are dewalt cups. They throw off shrapnel and it embeds itself in my jeans, shirt, and skin. Anyone have any suggestions of some brands and kinds of cups that work well without perforating the user?
Reply:Either one is going to shed wire but the wire wheel will be more durable and only use the wire cup when you have to.  Don't forget to use your safety glasses and a face shield when wire wheeling.
Reply:Use encapsuled brushes and make sure they have a high enough RPM rating for the grinder you are using.
Reply:My students in my welding classes can destroy a 3" wire wheel cup each day, so I had to stop providing them.  When they bring thier own they seem to last much longer!  I also have serious safety concerns with them using them due to the amount of wire they send into the air.
Reply:Originally Posted by weldingliferUse encapsuled brushes and make sure they have a high enough RPM rating for the grinder you are using.
Reply:You need to get the knotted cup wheels if your not already.  The unknotted ones will break off and stick into your pants and sometimes flesh.Miller 250x & Lincoln V205-TSmith Oxy-Prop torch
Reply:yeah the crimped one I have sucks. I will look into a notted one.Victor Journeyman OA TorchVictor Edge RegulatorsLincoln 180HD (240v) MIG/FCAWShark LT v7 CADMiller Digital Elite Helmet35 Milligrams of Insanity
Reply:Maybe they’re getting cheaper now. I have a box of wheels that dates back to the 40’s & 50’s. They take a licking and keep on ticking.
Reply:Originally Posted by RellsBritish General Henry Shrapnel is on my mind. Mainly because I have been picking pieces  of my latest wire cup out of my jeans for half an hour. What is with these new wire brushes that they dont last worth nothing. I like to Stick and Torch weld and am getting into FCAW. LONG AGO I gave up hand brushing welds as slow and annoying so I prefer to use my 4" grinder as a dedicated wire brush. The problem is that using a wire cup is the best for getting in small areas so I dont use a wheel. The cups I have been buying lately frankly SUCK. These are dewalt cups. They throw off shrapnel and it embeds itself in my jeans, shirt, and skin. Anyone have any suggestions of some brands and kinds of cups that work well without perforating the user?
Reply:The knotted ones are what we have used here.  Most of the students are using the Dewalt ones from Home Depot - the only reason they last longer is they know they spent $13.97 on each one.  The knotted ones still throw wires, trust me!
Reply:Originally Posted by transitMaybe they’re getting cheaper now. I have a box of wheels that dates back to the 40’s & 50’s. They take a licking and keep on ticking.
Reply:I have pretty good luck with Weiler-http://www.weilercorp.com/powpg.htmthey are real welders wire brushes, you get em at welding supply stores.Dewalt just buys chinese all purpose wire brushes, triples the price, and slaps their name on em- they sure dont have their own wire brush factory, much less one in Pennsylvania.
Reply:Go to www.weilercorp.com then click on Products, power brushes and then finally weld cleaning brushes. These are not cheap. They will throw a wire ocassionally. They are very aggressive.