Cutting with angle grinder

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I went out and bought a Porter Cable angle grinder hoping this would be my main method of cutting.  When I got it home I went to attach the cutting wheel but it didn't fit.  After reading the manual it said "this unit is not intended for cutting or buffing".  Suck.  I asked the lady at Farm and Fleet as to which angle grinder I could use for cutting as I could not use the one I bought.  She told me you cannot cut with an angle grinder and that those wheels are for air tools.  I don't believe her so now I turn to the experts for the real answer.  In lue of having my angle grinder for cutting I have been using my saws all and my old circ saw w/ metal blade for some bigger things.  Any other suggestions for cutting?   I am working 1/8 - 1/4" metal.  Thanks
Reply:Absolutely you can cut with an angle grinder.  Air, electric, no difference there.But to answer if you can cut with YOUR angle grinder, here's what we need to know.1) the wheel diameter the guard is sized for2) the RPMs.
Reply:4 1/2" grinder is the most dangerous tool i own. (at least five of em)...lots of torque. lightweight, keep 2 hands on that sumbitch cause it wants to kick up into yer face....get yerself a portaband..
Reply:The only thing my two grinder require is flipping the retaining nut on the blade depending on grinding or cutting blade in use.
Reply:I cut with my 4.5" grinders frequently.  Keep the guards on - I have a nice 6" scar on my stomach from a kickback.  I was two handing it and I am not small (6'4", 250+lbs).  The grinder is a little demon dying to get a chance to shed your blood - treat it with respect.I wear a leather apron now by the way.Hobart LX235Victor 250 Oxy-Acetylene Rig (welding and cutting)Bobcat 773F-350, 1999, 4x4, 16' 10K# trailerOutdoor Wood Burner - 10 cords/year
Reply:Hello natz803, as the others have already said, you can certainly use an electric grinder for cutting purposes. Additionally, as the others have included in various forms, correct grinder speed and wheel rating are of extreme importance. Make a careful note of the rpm of your particular grinder and when you are looking at the various offerings for cut-off wheels be sure that their speed ratings meet or exceed those of your machine. Use the guard in conjunction with a cut-off wheel, it may seem cumbersome in some instances, yet it will save your bacon just about everytime in the larger scheme of things. General safety rule is to keep as many body parts and particularly your face, out of the line of rotation of any grinding or cut-off wheel. If they are going to blow-up or catch and kick-back you don't want to be in line with the schrapnel or the physical force when this happens. Also, when you are using this combination, try to always have the wheel/disc pulling the grinder away from you and do not allow the grinding/cutting to be such that the wheel is pushing the grinder towards you. One more thing, cutting discs are not designed for grinding, only use them for their intended purpose, they are for cutting, grinding discs are for grinding. As one of the other folks mentioned, generally grinders have a backing washer and a retaining washer/nut, many of these are such that the thicker wheels require using one side of the retaining washer/nut, thinner discs require turning this item over in order to properly grip and retain the disc. Good luck, be safe, and best regards, Allanaevald
Reply:i have 3 grinders actually 1 has wire wheel 1 has cutter  and 1 has grinder that way i dont have to keep switching wheels back and forth my best advice is get a grinder w a paddle switch not a button that locks  you will see whymiller maxstar 150   hobart handler 210 w mig conversion hobart 250 arc force plasma cutter    boston ind cutting torch miller performance auto darkening helmet milwalkee 14in chop saw 10,000 watt generator huge drill press and industrial band saw
Reply:All i know is be very careful with the grinder, i just cut down to my fatty tissue march 8th and had stitches. it kicked and went through my glove...
Reply:Originally Posted by weldbead4 1/2" grinder is the most dangerous tool i own. (at least five of em)...lots of torque. lightweight, keep 2 hands on that sumbitch cause it wants to kick up into yer face....get yerself a portaband..
Reply:gow589,All I can say is you're the luckiest guy I know.To post up that crap for a newbie is both reckless and irresponsible.A high speed 4 1/2" grinder comes with a shield for the wheel and it's intended to be used.  If you choose to be reckless, that's your business, but don't encourage it for a new guy.  If you ever saw a cutting wheel explode/disintegrate, you'll be dang glad you had a shield between you and the wheel.  Pieces of that cutting disk are coming off at about 175 MPH and they are sharp.  They'll cut right thru a shirt or light jacket.Face shield and protective eyewear are also important when using a grinder for cutting as well as grinding.  Leather gloves will also help.  A good size chunk of cutting disk in the jugular or femoral artery will put you out of your misery in short order.Furthermore cutting circles/arcs is particularly dangerous with an angle grinder in that you're putting the blade in a bind which can cause fracture.  Best way I know to purposely "blow up a cutting disk" is to plunge it into the workpiece and then twist.As I said before, you do what you wish in your shop, but don't advocate unsafe practices for the new guys.To say "I've got a plasma cutter, but I can do a better job with my grinder" tells me one of two things.  You've either got a POS plasma, or you don't know how to use it properly.  For the cuts you're doing, I'd cut myself a pattern on the band saw and cut the material with the fine cut tips.  It would also be a lot safer than your grinder arc cuts.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Nice picture of sparks.  Where's the guard on your grinder?  Do you like your front teeth?SundownIII, I couldn't have said it better.  Cutting curves, NO!  The wheel is designed to fit right in the slot of the cut.  Any curve starts wearing the side of the wheel, and makes it dangerously likely to explode.  But, personally, while I like leather gloves to protect from sharp edges and sparks, I'm not big on gloves around ANY moving tool (drills especially, but grinders included).  Too likely to get your hand wrapped around the moving part.Never use cutoff wheels for grinding.  If you make contact with anything other than the perimeter, you will compromise the strength of the wheel, and it is likely to explode with dangerous consequences.Oh, and I've heard nothing but bad things about HF cutting wheels.  You get what you pay for.I burned through four new Dewalt cutoff wheels getting halfway through one piece, and finished the job with a nearly worn out Metabo wheel.  I've had good luck with Sait wheels as well, and Norton has been good for me too.BTW, is everything in that picture from HF?  I recognize the grinder, and the clamps, down to the little plastic spring clamp.  Is that their $3.99 denim apron?  LOLActually, I admit to owning one of their grinders, and most of the clamps in the picture.  Not as good as the name brands, but the stuff has its place.Back to the OP.  I'm still not sure which angle grinder you bought, BUT, off the shelf, just about all angle grinders come with the same style guard.  It's the guard that covers about 180 degrees, and is mostly open on the side opposite the machine.  That guard is designed to be used with type 27 (and possibly type 28) depressed center grinding wheels ONLY.  If your machine came with that guard (and the manufacturer didn't want to make a type 1 guard that could be purchased separately), then the manufacturer must say that the machine is not made for cutting.  The manuals for Metabo, DeWalt, and Milwaukee grinders (I didn't check any others) state that the machines may only be used for cutting, with a type 1 guard (which is sold separately) installed.  I guess PC doesn't make one.FYI, a type 1 guard is the type the gives a full 180 degrees of coverage on both sides of the wheel (so only the nut is exposed on the side opposite the machine).This site shows some of the differences:http://www.milwaukeeconnect.com/weba..._192391_192327and even shows guards for type 11 cup wheels (a completely different beast).Now, I personally cut on occasion with my Metabo 4.5" grinder, using the standard type 27 guard.  I'm sure most people here do.  What you do on your own time is up to you, but I hope this clears up why your machine says it isn't made to cut.I will add one thing:I ONLY cut with my Metabo grinder, and never with my HF.  The Metabo has a safety clutch which reduces the chance of a kickback if the wheel binds.  Metabo isn't the only one with this feature, BUT it is currently ONLY in the better grinders (DeWalt has one, Ridgid, Bosch, and Makita too), and not in one from HF.You may want to watch this:http://www.dailymotion.com/video/x8n...ture-in-a_techTheir electronic shutoff is interesting.  When I've bound the wheel in my Metabo, I just shut the switch.  I don't know who leaves an electric motor running, stalled . . .Same reason I went with a Bosch rotary hammer, and not an HF.  If the bit binds in the hole, the clutch is what keeps the machine from breaking your wrists.Last edited by rlitman; 03-25-2011 at 11:28 PM.
Reply:Well sir, I have a 4 1/2 angle grinder and I can tell ya I will be gettin a porta band with a good bi metal blade as soon as I can sell a hog trap or two. grinding is ok, no more cutting tho a just have had  too many close close.  I wouldnt have my gut if it wasnt for my long shirt getting tangled around the blade.  Well I am off my box now.
Reply:Originally Posted by SundownIIIgow589,To say "I've got a plasma cutter, but I can do a better job with my grinder" tells me one of two things.  You've either got a POS plasma, or you don't know how to use it properly.  For the cuts you're doing, I'd cut myself a pattern on the band saw and cut the material with the fine cut tips.  It would also be a lot safer than your grinder arc cuts.
Reply:Originally Posted by rlitmanBTW, is everything in that picture from HF?  I recognize the grinder, and the clamps, down to the little plastic spring clamp.  Is that their $3.99 denim apron?  LOL
Reply:I use a cutoff disc to cut off bolts....or quick, short cuttof jobs. When you figure labor and cutoff wheel cost....it is far less expensive to cut with a plasma. Far less! And a bit safer.Here is me cutting a couple of gussets from 5/8" plate with my hand plasma....Jim Colt
Reply:Originally Posted by gow589You gonna make fun of my socks next?When some one is treated like dirt when he is good at what he does by people who think they know everything, there is no reason to be here.
Reply:gow589,Don't expect people who know what they're talking about to applaud your stupidity.Using cheap tools (grinders/cutting disks) improperly is a prescription for disaster.Just because you haven't been bit yet doesn't mean it's not coming.  You keep poking the dog, the dog is going to bite you.  It's not a matter of IF, it's a matter of WHEN.I went back and looked at several of your previous posts.  Several of them were related to grinding/cutting accidents.  Several even showed pictures of the results, so I know you're aware of the potential dangers.  To continue with your present "technique" is not only dangerous, it's flat out stupid, and I don't know many real craftsmen who are stupid.I could show people on the board how to build a pipe bomb, but I'm not going to.  What you're doing is just as dangerous.  Emergency rooms, throughout the country are filled with people who swore "It can't happen to me".Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Well Sundown, you win. Your the alpha dog or alpha axxhole. Your forum your can have it.
Reply:Originally Posted by gow589Well Sundown, you win. Your the alpha dog or alpha axxhole. Your forum your can have it.
Reply:Just thought I'd bump this thread since it seems to go hand in hand with another post on the Safety Forum.This thread covers many of the ways "how not to use a grinder".Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Definitely be careful. Those suckers will scatter everywhere.
Reply:i also use the sait .045 cutoff wheels....  they seem to be the best ive bought and used so far... i always use a face shield when using a cutoff wheel... ive used no name brands and name brands that when they decide to blow apart they blow apart...    i use cutoff wheels to deburr also, does a nice light chamfer just dont put any pressure on it, let the wheel do its thing..  i also have to agree with jim colt, i use to have a small 25amp plasma that was handy it would do 3/16 but that was it, it could do thicker but you had to slow it way down.. moved to a 40amp plasma and its pretty nice and pretty fast.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Just jumping in here to say that I agree that an angle grinder should never be used without a guard and personal protective equipment. I have not always done so; but I have been lucky.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:the problem with angle grinders, and i didnt read this on any posts, if it was there sorry for repeating...but when you cut with an angle grinder (or die grinder, chop saw, etc) is cutting wheel doesnt just break. it sprays out at you. guard or no guard your gonna get cut.a guy on the job site stressed the wheel on a chop box and it exploded everywhere. him and his partner (his partner was holding up heavy gauge studs) got sprayed with the wheel. the holding the studs got a couple cuts nothing big at all. but the guy cutting....he spent hours at the hospital while they picked out the fibers from the saw blade and got stitches...the doctor told him he had wear vicks vapor rub on his arm because the heat would draw out any fibers they couldnt get to. ive cut through thick stuff with a 5" cutting wheel on a grinder and had a close call. from now on if it needs to be cut its gonna be torched off. its not worth it to me.i was on a scissor lift and i was unloading studs through a hole in the ceiling to the next floor up. all i did was push the studs with very little force and i split my hand open. if metal was shot back at you forget it. if im grinding off a bolt thats one thing. but anything more than that forget it..the grand ol' opry aint so grand anymoremiller maxstar 150sworking on an oxy/acet set up
Reply:bag on harbor freight grinders if ya want but ive got one thats outlasted 3  name brands and cut concrete tile stone porcelain stucco steel etc and still going strong used a good number of there cutting discs they dont last long and can shatter easy but are cheap and plentiful when needed be careful them things are dangerous350P 30A spool gun cut master 51  syncro 250 other stuff " take a dog off the street and make him prosper and he will not bite you sad the same cannot be said for man" i didnt use punctuation just to piss you offzipcuts are the cats meow in a lot of situations, but a torch also has it's place as you cannot zipcut or chopsaw everything (well, you can, but...)  I think a lot of the problems regarding the use of a cutting disk on an angle grinder relate to the improper use of the tool.  I've only ever blown up one zipcut, but I was wearing a face shield (thankfully!)  The trick is to let the disk do the cutting and not to force it.  Before using a disk, inspect it for cracks and make sure you are using the right connectors (holders?) for the job!  For instance, I have a backing pad that lets me grind on the flat with a 1/4" grinding disk or pipe disk, and another set which I use for zipcuts/pipedisks when I need to cut/grind on edge.  Likewise, you'll be able to tell if you have the right setup for the disk as one is countersunk for blades with that lip or whatnot, and some are made to hold a disk straight.  I'm horribly bad at explaining stuff like this, but I can take pictures if it helps!I'm actually interested in trying out one of those portable bandsaw gizmo's as I can think of several situations where one would come in handy!A grinder is a grinder and I like my hemi orange spray bombed Dewalt!  If it works, it works!Last edited by mb_welder; 04-12-2011 at 12:19 AM.
Reply:Originally Posted by SundownIIIgow589,Don't expect people who know what they're talking about to applaud your stupidity.Using cheap tools (grinders/cutting disks) improperly is a prescription for disaster.Just because you haven't been bit yet doesn't mean it's not coming.  You keep poking the dog, the dog is going to bite you.  It's not a matter of IF, it's a matter of WHEN.I went back and looked at several of your previous posts.  Several of them were related to grinding/cutting accidents.  Several even showed pictures of the results, so I know you're aware of the potential dangers.  To continue with your present "technique" is not only dangerous, it's flat out stupid, and I don't know many real craftsmen who are stupid.I could show people on the board how to build a pipe bomb, but I'm not going to.  What you're doing is just as dangerous.  Emergency rooms, throughout the country are filled with people who swore "It can't happen to me".
Reply:Originally Posted by SEAREver see an episode of "Orange County Choppers" ? 4.5" cut-off wheels, no guards, no gloves
Reply:simple4.5"  grinder with  " toggle/sliding switch "      =    grinding wheels4.5"  grinder with " paddle switch "          =         cut-off wheeli ONLY cut with a grinder WITH  a  " paddle switch " soon as a chunk blows off the wheel , you INSTANTLY release the switch the broken wheel stops on the corner of the metal your cutting into every time ...........with a toggle/sliding switch......your deaddumb        thermal arc 252i  -  millermatic 350P -   miller XMT, cp300ts, 30a 22a feeders, buttload of other millers, handfull of lincolns, couple of esabs  -   Hypertherm 1250 G3