6" cut-off wheel in a bench grinder

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6" cut-off wheel in a bench grinder Michael Koblic 05-27-2008
Posted by Michael Koblic on May 27, 2008, 1:31 am
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 I have to cut 2 perfectly matching slots in a 5 mm thick flat semicircular
piece of steel, each 15 mm by 5mm.
As per suggestion on another thread I doubled up on the hacksaw blades. This
gave me only just over 2 mm. Cutting this length with a file is not a
prospect I relish. I tried with a 3/32 cut-off wheel in a 4-1/2" grinder.
This works but holding the grinder in exactly right plane is tricky.

I wondered: what if I put a 6" cut off wheel into my bench grinder. I would
have access and control. Even if the wheel produced a thinner slot, one
could control two passes this way more easily than with a hand-held grinder.

Is anything like this feasible? has anyone done this? The maximum speed for
the 6" cut-off wheels easily exceed the 3,500 rpm of the grinder. At this
point I cannot see any other safety issues beyond those related to using a
bench grinder in the normal fashion.

Failing this, what is the maximum number of hacksaw blades anyone tried
cutting with at once?

--
Michael Koblic,
Campbell River, BC




Posted by on May 27, 2008, 6:56 am
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> I have to cut 2 perfectly matching slots in a 5 mm thick flat semicircular=

> piece of steel, each 15 mm by 5mm.
> As per suggestion on another thread I doubled up on the hacksaw blades. Th=
is
> gave me only just over 2 mm. Cutting this length with a file is not a
> prospect I relish. I tried with a 3/32 cut-off wheel in a 4-1/2" grinder.
> This works but holding the grinder in exactly right plane is tricky.
>
> I wondered: what if I put a 6" cut off wheel into my bench grinder. I woul=
d
> have access and control. Even if the wheel produced a thinner slot, one
> could control two passes this way more easily than with a hand-held grinde=
r.
>
> Is anything like this feasible? has anyone done this? The maximum speed fo=
r
> the 6" cut-off wheels easily exceed the 3,500 rpm of the grinder. At this
> point I cannot see any other safety issues beyond those related to using a=

> bench grinder in the normal fashion.
>
> Failing this, what is the maximum number of hacksaw blades anyone tried
> cutting with at once?
>
> --
> Michael Koblic,
> Campbell River, BC

Put two cut off wheels tight together =3D wider slot...

Posted by Steve W. on May 27, 2008, 8:08 am
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Michael Koblic wrote:
> I have to cut 2 perfectly matching slots in a 5 mm thick flat semicircular
> piece of steel, each 15 mm by 5mm.
> As per suggestion on another thread I doubled up on the hacksaw blades. This
> gave me only just over 2 mm. Cutting this length with a file is not a
> prospect I relish. I tried with a 3/32 cut-off wheel in a 4-1/2" grinder.
> This works but holding the grinder in exactly right plane is tricky.
>
> I wondered: what if I put a 6" cut off wheel into my bench grinder. I would
> have access and control. Even if the wheel produced a thinner slot, one
> could control two passes this way more easily than with a hand-held grinder.
>
> Is anything like this feasible? has anyone done this? The maximum speed for
> the 6" cut-off wheels easily exceed the 3,500 rpm of the grinder. At this
> point I cannot see any other safety issues beyond those related to using a
> bench grinder in the normal fashion.
>
> Failing this, what is the maximum number of hacksaw blades anyone tried
> cutting with at once?
>

Go get one of the cheap tile saws that use a 4 1/2" grinder as the power
source. Replace the diamond blade with a cutoff wheel. Now you have a
flat table with built in cooling, the guide rails will steady the
grinder and give you a 90 degree cut.

I have one here that I used for a long time.

--
Steve W.

Posted by Michael Koblic on May 28, 2008, 3:30 am
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Really? That is interesting! It could solve all kinds of other problems for
me. Canadian Tire have a small tile saw on sale from time to time for $50.

So you did not have any problems with the plastic melting? And you used
standard 4-1/2" cut-off wheels with the water bath? I just had a look at the
Dewalt tile saw manual. They warn strenuously against doing just that...BTW,
what is the rpm on the tile saw - same as an angle grinder?

--
Michael Koblic,
Campbell River, BC

>
> Go get one of the cheap tile saws that use a 4 1/2" grinder as the power
> source. Replace the diamond blade with a cutoff wheel. Now you have a flat
> table with built in cooling, the guide rails will steady the grinder and
> give you a 90 degree cut.
>
> I have one here that I used for a long time.
>
> --
> Steve W.



Posted by Steve W. on May 28, 2008, 8:28 pm
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Michael Koblic wrote:
> Really? That is interesting! It could solve all kinds of other problems for
> me. Canadian Tire have a small tile saw on sale from time to time for $50.
>
> So you did not have any problems with the plastic melting? And you used
> standard 4-1/2" cut-off wheels with the water bath? I just had a look at the
> Dewalt tile saw manual. They warn strenuously against doing just that...BTW,
> what is the rpm on the tile saw - same as an angle grinder?
>

Nope, no problem as long as I kept the water flowing. I would bet the
plastic would melt without coolant. Don't try to cut the notches all in
one pass and let the part cool down a bit and it would reduce the risk
to about zero.

I can't imagine why a company that also make metal cutting tools would
tell you not to buy a cheaper tool to do the same job ;-)

The tile saw I have uses the same grinder that I use for normal use, it
does have a rubber sleeve that keep water out but other than that it's
the same design.

--
Steve W.

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