Yes, I know. She should be...
Yes, I know. She should be wearing long sleeves.
When I first started messing with 4x4s and metal, I bought an angle grinder because they are so darn useful. You can cut, shape, clean, notch, prep, and finish metal with a simple angle grinder and a handful of different wheels. In fact, when I was a kid I learned how to use my dad's bench grinder and was even caught cutting wood with that old grinder. Needless to say, Dad was not pleased.
A grinder is simply an electric motor that you attach different wheels to. The motor spins at a given rpm, and the wheel does the grinding. I know guys who built their whole trail rig with just a grinder and a drill, but for this month I'll concentrate on the different types of grinders, the attachments, and safety.
I use a coarse stone wheel (right) for removing old welds or brackets since it cuts with the most ferocity. The thin cutoff wheel (center) cuts metal quickly, but these wheels can damage easily if they get caught while cutting. The flap wheel (left) consists of many small pieces of sandpaper stacked up with a soft backing, and the paper is available in different grit numbers. These are great for cleaning off paint or surface rust, removing deep gouges from the stone wheel, or deburring cut pieces of metal.
Angle grinders come in many...
Angle grinders come in many shapes and sizes, but the two most useful are the 41/2-inch and the 7-inch. Most dedicated fab shops have a plethora of 41/2's outfitted with different wheels, while they save the 7-inch grinders for jobs where serious amounts of material need removing. The big grinders are heavy and can be dangerous, but the larger wheel results in a flat final surface on the metal you are grinding.
Safety gear is important when...
Safety gear is important when grinding. However, many folks remove the factory guards on their grinders for ease of use. I understand this decision, but can't promote it and definitely don't condone grinding without at least gloves and safety glasses. If you're using a wire wheel, use a facemask also unless you like steel whiskers in your beard. Also note the can of brake cleaner near the grinder. Bad idea. Sparks could light off the can.
Before you grind, check out...
Before you grind, check out your surroundings. Will you be throwing sparks and cinders into your engine intake? Onto your buddy beside you? Toward a spare can of fuel or a trash can full of paper? Also, be careful to clean any grinding residue off your vehicle, as it quickly oxidizes and would leave your paint with little rust spots everywhere.
If you come across any type...
If you come across any type of grinding wheel with a chunk missing, throw it away. Otherwise it will come apart at speed, sending chunks everywhere, maybe even into your face or arms.
Wire wheels are great for...
Wire wheels are great for cleaning off paint and rust and for cleaning tubing for welding. A cup brush on an angle grinder is also great for cleaning into corners or small places like on a frame.
Another great grinder to own...
Another great grinder to own is a die grinder. These attach the wheel directly to the output of the grinder. Plus you can get electric, rechargeable, or pneumatic die grinders; a variety of cutoff, flat, and stone wheels; and bits.