Cutting tools

[sunroof]

So here is my collection of cutting tools:

They all have their uses but they all have shortcomings. The dremel is nice because it makes a narrow kerf but the wheels don't last long and the dremel itself has very little torque for cutting. The air saw is nice but not great for making straight lines. The electric grinder with a diablo cutting wheel on it goes thru metal like a hot knife thru warm butter but it's heavy and large and impossible to make precise cuts. The air grinder is a great tool as well, precise, lots of torque and light but I can't find 0.040" cutting wheels for it. This is what I really want: 3" - 3/8 arbor 0.040 cutting wheels. And no Diablo don't make 'em. If I can find wheels for it the air grinder will do so much for me.

Diablo wheel, beautiful to cut with but too large for what I want.

Don

[modok]

Going by eyeball accuracy can be the thickness of a blade or better.
I always draw a line with marker or template/spraypaint and then cut on the line.

The guard on the angle grinder is preventing you from seeing the the line then it's in the way, should be moved or modified or well, you know. Get really good safety glasses, the goggles or the ones with shields all around the edges.

Dewalt is making some good cutoff wheels, better than the diablo ones. I used to use Forney brand but local store quit carrying it which is a shame.
http://www.dewalt.com/tool-parts/abrasives-bonded-...heels.aspx

To make the dremels more powerful I run with a transformer or variac 140 or 160 volts. Really brings it to life!!

[kielbasa]

I agree about the Dewalt cut off wheels. I bought a 5 pack 4months ago and I'm still on the first blade, and only used up a 1/4" of blade. That includes lots of sheet metal cutting, and cutting 10 12mm wheel studs. They cut clean and smooth.

It takes practice to cut really well with an cut off wheel on a grinder. I always mark what I need to cut and cut a hair larger. Then I can fine tune it on the bench grinder or a hand file. Using tape works really well for guiding your cuts.

I also agree you need to ditch the shield on the grinder. They make it a pain in the ass to cut. Just make sure you cut in a way where your not throwing sparks up in your face.
_________________
Gotta give my props to:
Wolfsburg Motorsports
Dubbers Toy Box
Jeff's VW Speed and Fab
4inbore.com
Kielbasa Industries

[esde]

It's too easy to get off of your mark when cutting sheet metal, so rarely do I even attempt to get it right the first time. Usually I aim to cut about a 1/16" away from my target line with whatever suits the job best, plasma, wafer wheel on a grinder, sawzall. Then I use my grinder with a 60 grit flap wheel and carefully buzz the sheet exactly to the line. For inside corners where the grinder won't fit, get some carbide burrs for the pneumatic die grinder. They throw big chips, so eye goggles are a must.

[sunroof]

Thanks guys. I will try and find the Dewalt cut-off wheels.

Don

BTW I tried cutting with the angle grinder with the shield off and it scared the crap out of me! I've had enough accidents over the years to leave more than a few scars and bad memories.

[Mike Fisher]

I took my guard off to better cut out solid body sections, but you do have to be careful with your fingers & thumbs!
_________________
https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[sunroof]

I ordered 3 of these:

http://www.amazon.com/gp/product/B000LNXX4G/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

I'll let you know how it works out. Funny, in Canada there is no such product, I had to order it from the US.

Don

[esde]

Almost forgot one more
pneumatic nibbler, its really nice for places that blades won't fit
http://www.harborfreight.com/16-gauge-air-nibbler-96661.html
I don't have this one, mine if a good bit more $$. No idea how the cheap ones hold up

[Northof49]

I would be extremely hesitant to remove the guard from a grinder. I have heard of several deaths resulting from exploding grinder wheels where the user removed the guard. Reposition it, or yourself if necessary, but don't risk your life by removing. Despite it seeming like an annoyance, it is there for a reason and should be between you and the edge of the blade. Position yourself off to the side if necessary to improve your view of the cutting surface. I regularly experience shattering of cutting disks when they catch on something.
_________________
1958 Karmann Ghia owner

[theKbStockpiler]

I have a broken HF nibbler. It worked better than a expensive one I have but a part broke that converted the rotory motion to the up and down motion. I can't get the head off to try to fix it.
_________________
My beetle is not competing with your beetle. I have the yellow beetle in my town. There is a red one, a green one ......
Use all safety devices including a mask.

[sunroof]

I have an electric nibbler! I forgot all about it. I will have to update my photo.

Don

[modok]

[Der Speed Shack]

double cut shears make nice clean cuts, but have a wide kerf. when i use them im usually not to concerned with the kerf as im replacing that metal