Grinders serve a bevy of useful functions ranging from rust removal and blade sharpening to polishing and buffing. With a wide array of available accessories, you’ll find a grinder makes a versatile and useful addition to your tool collection. Whether you choose a bench-top or portable unit, there are many different sizes, power levels and features to select from. It’s important to hone in on what types of activities you plan to use the grinder for most frequently to help determine which one is right for you. Consider the following questions to narrow down your selection:
- What applications will you use your grinder for?
- Which type is best suited to the tasks and materials?
- How large of a grinder do you need?
- What attachments and wheels would be useful?
- What features and options would you like to have?
Types, Wheels, Safety and Operating Tips
You’ll first need to determine what type of grinder you want. If you do a lot of grinding work, it may make sense to have a bench-top grinder in your workshop as well as a portable unit for smaller tasks around the home or on the jobsite. Look for grinders that feature large, easily accessible switches that you can manipulate even when wearing gloves. High-powered motors are essential for heavy-duty usage, and a properly balanced grinder will provide the comfort you need for extended periods of use. Make sure you can switch wheels easily to tackle a wide range of tasks, and be sure to closely adhere to safety guidelines when operating the unit.
Types and Size Considerations: Bench-top grinders are ideal for heavy-duty cleaning, polishing, grinding and sharpening. They feature two wheels, usually one with a lower grit for coarse work and one with a higher grit for finer, more detailed work. Their wheels typically range in diameter from around 5" to 10" and spin at around 3,500 rpm. Portable and angle grinders are slightly smaller, having one wheel that usually ranges from around 2" to 7" in diameter. These units often have a side handle that makes them easier to control by allowing you to use both hands. Tuck-point grinders are specialized portable grinders that are used to remove mortar from brick. This process creates a great deal of dust, so make sure the grinder has an effective guard in place to protect you. Also consider wearing a dust mask or respirator.
- Horsepower usually ranges from 1/5 hp to 1 hp or greater
- Grinders with slower speeds create less heat
- 4" or 4-1/2" grinders are ideally sized for a wide range of tasks
- In many cases, more amps means more power
- Top handle positions make tuck pointing easier
Wheels: Grinders can be used for removing both ferrous and nonferrous metals as well as various applications with wood, paint, rust, concrete, masonry, marble, slate, stone and tile. They can also brighten and polish metal, buff, grind, sand, cut and notch. You can even use them to deburr or level surfaces. The key to their versatility lies in the wheel. Different types of wheels are used for different purposes, and knowing which wheels are most effective for which tasks is crucial to efficient operation. Use the chart below to help determine which wheels you’ll need to use for a given job:
| Wheel Type | Uses and Points to Consider |
| Silicone Carbide |
|
| Fiber |
|
| Buffing |
|
| Sanding |
|
| Wire/Brush |
|
| Flapper |
|
| Aluminum Oxide |
|
| Dry-Cut Diamond |
|
| Cutoff |
|
| Grinding |
|
| Tuck Pointing |
|
Safety and Operating Tips: Grinder wheels spin very quickly, so it’s important to keep your hands and clothing out of the way. Safety glasses are essential to protect your eyes from sparks and flying debris. Grinding creates a great deal of heat and can create sparks, so remove flammable materials from your work area. Too much heat will weaken the material you are sharpening, so wet down your work surface periodically to keep it cool. Make sure the wheel is spinning away from sharp edges rather than into them to avoid kickback. Be sure to avoid securing the spindle nut too tightly, as doing so may damage the flanges and wheel. Grinders with fully adjustable toolrests are easier to operate.
- Wear gloves to protect your hands and a mask to protect your lungs
- Don’t tamper with built-in guards designed to deflect dust and sparks
- Unplug unit when changing wheels
- Use lighter-impact wheels when cleaning masonry
- Ensure that your work area has bright, shadow-free lighting
Features
Water Trays: Units with water trays provide a convenient place to cool down metal as you grind, helping to prevent it from overheating and losing its temper.
Variable Speed: Motors that allow for speed adjustment let you grind on slower speeds to prevent heat buildup.
Vacuum Attachment: Look for this feature on tuck grinders. A vacuum attachment allows you to connect your grinder to a vacuum to eliminate the ample amounts of dust created when tuck pointing brick.
Performance and Durability: Metal gear housing aids in high-torque applications. Grinders with machine-cut gears generally last longer and require less maintenance, saving money over the long run, despite a slightly larger up-front investment.
External Brushes: When the brushes are located on the outside of the grinder, they’re much easier to change and replace, reducing downtime and helping you get back to work faster.
Labyrinth Construction: Grinders with this design feature a self-contained motor that is protected from debris, giving it longer life and reducing the likelihood of damage.
Lighting: Built-in lamps provide better illumination of the work area for increased accuracy.
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