I have a few 30 year old 4 1/2 Dewalt angle grinders that I have not used in a few years. I have a few metal projects coming up and so is Christmas . Are new 4 1/2 angle grinders night and day better and if so, how? What is the best out there (Christmas gift) ? Is even the cheap HF one better than my old 30 year old ones? I never used a flap wheel, what are they good for?
4 1/2 angle grinder question
- Thread starter johninct
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I would use the 30 yr old grinders without hesitation.
if you want to be sure of the condition, open it up, spin the bearings, look at the brushes , the commutator and bevel gears. Search Dean Doherty on you tube , he has a lot of repair videos if you need knowledge on pulling them apart & inspecting etc. Virtually Nothing today is built better than it was 30 yrs ago IMO
if you want to be sure of the condition, open it up, spin the bearings, look at the brushes , the commutator and bevel gears. Search Dean Doherty on you tube , he has a lot of repair videos if you need knowledge on pulling them apart & inspecting etc. Virtually Nothing today is built better than it was 30 yrs ago IMO
I would think newer ones in theory have better tolerances and therefore less vibration. Some newer ones have better handles with rubber cushioning to help with vibration. I personally wouldn’t upgrade if the one I had was working though. I’d run it until it quits, but that’s just me.
HF has levels, so the low level ones I’d expect to have higher vibration and not last as long as the higher end ones. A friend of mine had one of the super cheap old orange housing HF grinders that had insane vibration. Lasted 15 years or something like that.
Flap discs are great when you want to use a little more finesse in removing material.
HF has levels, so the low level ones I’d expect to have higher vibration and not last as long as the higher end ones. A friend of mine had one of the super cheap old orange housing HF grinders that had insane vibration. Lasted 15 years or something like that.
Flap discs are great when you want to use a little more finesse in removing material.
I've mostly switched over to sanding discs with backer pads ; cheaper, seem to last longer, more available grits and I seem to have better control with them
Dave455
Well-known member
The answer is, it depends on the grinder.
Some newer grinders are in a different league compared to the older ones. Features such as dust protection, soft start, anti kickback, brushless motors, variable speed and paddle switches are all available if you want them.
Best, very difficult to say as it’s so subjective. I have grinders from Fein, Metabo and Makita. All are superb in some respect. Fein I think are probably about the best “all round” (that I have experienced) provided you go for a German made one. Not all are. Metabo are probably the toughest, again, provided you go for German made, not “Metabo HPT”.
Makita can be beautifully smooth, but with all these manufacturers there are huge variations across the range, and you can’t compare the cheapest with one costing five times the price. I think Makita offer 9 or 10 different grinders in 4 1/2” alone. I think about 15 in 5 inch. I’ve only used one DeWalt, a cordless tool. Thought it was quite decent.
Despite owning many, I don’t particularly like using grinders, and I absolutely hate the cheaper ones. I bought one for a friend to do one job for me. I thought it was always handy to have a cheap grinder. I was wrong - the thing was awful. The design was dreadful, the switch was hard to reach, and so hard to turn off that the thing was dangerous. The vibration was horrendous, and the noise level left me with ringing ears despite using my best ear defenders!
So I’d say stick to your DeWalt in preference to a newer cheaper grinder, but be aware that there may be better newer grinders that are much nicer / safer to use.
Generally, flap discs are for the things you think you would use a metal grinding disc for, but they are easier / safer to use, and give a better finish.
But If you’re doing different jobs you generally want as many different options as possible. For my 4 1/2” grinders I have thin cutting discs, grinding discs, wire cup brushes, flapwheels, sanding discs, masonry cutting disc (diamond) and masonry grinding discs.
More value in accessories than some of the grinders!
Some newer grinders are in a different league compared to the older ones. Features such as dust protection, soft start, anti kickback, brushless motors, variable speed and paddle switches are all available if you want them.
Best, very difficult to say as it’s so subjective. I have grinders from Fein, Metabo and Makita. All are superb in some respect. Fein I think are probably about the best “all round” (that I have experienced) provided you go for a German made one. Not all are. Metabo are probably the toughest, again, provided you go for German made, not “Metabo HPT”.
Makita can be beautifully smooth, but with all these manufacturers there are huge variations across the range, and you can’t compare the cheapest with one costing five times the price. I think Makita offer 9 or 10 different grinders in 4 1/2” alone. I think about 15 in 5 inch. I’ve only used one DeWalt, a cordless tool. Thought it was quite decent.
Despite owning many, I don’t particularly like using grinders, and I absolutely hate the cheaper ones. I bought one for a friend to do one job for me. I thought it was always handy to have a cheap grinder. I was wrong - the thing was awful. The design was dreadful, the switch was hard to reach, and so hard to turn off that the thing was dangerous. The vibration was horrendous, and the noise level left me with ringing ears despite using my best ear defenders!
So I’d say stick to your DeWalt in preference to a newer cheaper grinder, but be aware that there may be better newer grinders that are much nicer / safer to use.
Generally, flap discs are for the things you think you would use a metal grinding disc for, but they are easier / safer to use, and give a better finish.
But If you’re doing different jobs you generally want as many different options as possible. For my 4 1/2” grinders I have thin cutting discs, grinding discs, wire cup brushes, flapwheels, sanding discs, masonry cutting disc (diamond) and masonry grinding discs.
More value in accessories than some of the grinders!
Bad Habit
Well-known member
Just be careful when sanding thin edges. Recently had one catch and throw it back at me. Let's just say we had a personal moment and a sanding disc into your shirt is not recommended. Minus a favorite shirt and my belly is healing nicely, thanks for asking
A 30 year old angle grinder isn't necessarily better or worse than a new one.
It all depends on the specific model grinders being compared.
Amps (power) of the motor matter. A lot IMNSHO. ~4 amp motors can be bogged down with moderate pressure, depending on the attachment. ~8 amps motors are more powerful (Captain Obvious here
). 11-12 amp motors have even more power.
I have some cheapo HF angle grinders, they work but as I have added grinders to my stable I usually now reach for one of the 'better' grinders instead. Smoother running, better ergonomics, more power, another 10-20% rpms too (works faster.
) but still within the attachment rpm limits. (Do NOT exceed the attachment rpm limits!).
I wouldn't automatically scrap your 30 year old grinders, but I would check the brushes and clean and lube the gear box (30 year old grease probably isn't very lube-ey any more). Spin the spindle by hand and see if it feels OK. If yes, fire it up and evaluate the operation. If the brushes are worn and no longer available, then that simplifies your options.
Fein (German), higher end Bosch, then maybe higher end Dewalt would be my rough ranking order. A lower end HF unit might be ~$20 or so, a higher end grinder can run $100+. You have to decide where your price/performance balance point is.
A flap disk can help remove material and blend a little more smoothly than a hard grinder wheel. More grit options too. But they are expendable and can wear out quickly. I usually use flap disks instead of a hard wheel but I'm not a production shop.
It all depends on the specific model grinders being compared.
Amps (power) of the motor matter. A lot IMNSHO. ~4 amp motors can be bogged down with moderate pressure, depending on the attachment. ~8 amps motors are more powerful (Captain Obvious here
). 11-12 amp motors have even more power. I have some cheapo HF angle grinders, they work but as I have added grinders to my stable I usually now reach for one of the 'better' grinders instead. Smoother running, better ergonomics, more power, another 10-20% rpms too (works faster.
) but still within the attachment rpm limits. (Do NOT exceed the attachment rpm limits!).I wouldn't automatically scrap your 30 year old grinders, but I would check the brushes and clean and lube the gear box (30 year old grease probably isn't very lube-ey any more). Spin the spindle by hand and see if it feels OK. If yes, fire it up and evaluate the operation. If the brushes are worn and no longer available, then that simplifies your options.
Fein (German), higher end Bosch, then maybe higher end Dewalt would be my rough ranking order. A lower end HF unit might be ~$20 or so, a higher end grinder can run $100+. You have to decide where your price/performance balance point is.
A flap disk can help remove material and blend a little more smoothly than a hard grinder wheel. More grit options too. But they are expendable and can wear out quickly. I usually use flap disks instead of a hard wheel but I'm not a production shop.
dnschmidt
Well-known member
Every company has a specialty. Sawzall it's Milwaukee, Routers DeWalt and Bosch, Angle grinders German Metabo have been the best followed by Makita, Milwaukee and Bosch. These are very simple tools. A motor spinning a bevel gear and that's about it. For cordless I like Milwaukee since I have about 100 Milwaukee batteries. Many people use DeWalt and have for decades. This a a well developed tool and just about everybody knows how to make a good one.
finn
Well-known member
My oldest grinder is a Craftsman “ Industrial” circa 1979 pr so. I bought Skil, Bosch, Harbor Freight, Milwaukee, Makita, Metabo, Porter Cable, and a Dewalt Flexvolt over the years..
One of the improvements I observed over the years is the quick change / toolless disc change systems seem common now. All my older grinders require some sort of scanner, and every brand had a different, non interchangeable spanner to change the disc.
Otherwise, to me, a grinder is a grinder. I’m not a heavy user who leans into the workpiece, but rather tend to let the machine do the work to avoid overheating the work. The more powerful grinders in my mix tend to be used for heavy work, but the cheapest ones are lighter and less fatigue inducing, and I sometimes favor them, especially for stripping paint, etc. I like to have several grinders on hand with various discs, cutoff wheels, strippers, and wire wheels.
Grinders are actually pretty inexpensive if you stay away from the boutique brands or models. Last year I bought two Porter Cable grinders from TSC for either $20 for the pair or each. This year I bought an Amazon “used” Metabo for $87. I suspect they’ll both outlive me at this point.
One of the improvements I observed over the years is the quick change / toolless disc change systems seem common now. All my older grinders require some sort of scanner, and every brand had a different, non interchangeable spanner to change the disc.
Otherwise, to me, a grinder is a grinder. I’m not a heavy user who leans into the workpiece, but rather tend to let the machine do the work to avoid overheating the work. The more powerful grinders in my mix tend to be used for heavy work, but the cheapest ones are lighter and less fatigue inducing, and I sometimes favor them, especially for stripping paint, etc. I like to have several grinders on hand with various discs, cutoff wheels, strippers, and wire wheels.
Grinders are actually pretty inexpensive if you stay away from the boutique brands or models. Last year I bought two Porter Cable grinders from TSC for either $20 for the pair or each. This year I bought an Amazon “used” Metabo for $87. I suspect they’ll both outlive me at this point.
jsaw
Well-known member
Been there done that a couple timesJust be careful when sanding thin edges. Recently had one catch and throw it back at me. Let's just say we had a personal moment and a sanding disc into your shirt is not recommended. Minus a favorite shirt and my belly is healing nicely, thanks for asking
I try to work so that if the wheel catches that it pulls the grinder away from Me
KnurledNut
Well-known member
Dewalt Corded tools from 30 years ago were industrial grade. I would have no issue using them.
Do you know which model they are?
I have an old one of these that I still use occasionally. Its a little noisy but running strong. Being able to thread the handle in either side or the top was a nice feature:
(As pictured in the ‘94 catalog)
Do you know which model they are?
I have an old one of these that I still use occasionally. Its a little noisy but running strong. Being able to thread the handle in either side or the top was a nice feature:
(As pictured in the ‘94 catalog)
jblnut
ALLIANCE MEMBER
You don’t just spin the nut tight by hand, grab onto the disc and give it another tightening type spin while still holding the lock button and call it good ? Same for loosening. Never had to use a wrench to loosen it.
Every one of those blasted two pin spanners as well as the silly quick change nuts get pitched under the workbench never to be seen again. I’ve never had a disc come loose or any issues from doing it that way.
I have this exact grinder bought in the mid 90’s.Dewalt Corded tools from 30 years ago were industrial grade. I would have no issue using them.
Do you know which model they are?
I have an old one of these that I still use occasionally. Its a little noisy but running strong. Being able to thread the handle in either side or the top was a nice feature:
(As pictured in the ‘94 catalog)
I’m sure others use their grinders more than I but this grinder has served me well.
I have other, cheaper, grinders so that I don’t have to change disks. The DeWalt is the one I keep tool box. I love the top handle position. It makes cutting a straight line so much easier IMO.
Anyone have a recommendation on gear box lube? I can’t remember what I used last time.
Edit: Of course there is a GJ thread covering the gear lube.
https://www.garagejournal.com/forum/threads/grease-for-angle-grinder-gearbox.420624/
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finn
Well-known member
I still have ten fingers and plan to keep it that way.
esben57
Well-known member
Bought a cheapo corded for a certain task and the gearbox melted.
Bought twice this time Makita, excellent .
Bought twice this time Makita, excellent .
Joemctag
Well-known member
I VERY rarely need to get one of the spanners. They’re hanging in my shop, probably a dozen different ones. If I , for instance, drop the grinder snd break a cutting wheel where I can’t undo it by hand ,I get a Channel-lock and unscrew the nut.
Wrench97
Well-known member
The only improvement in the last 30 years would be the move to cordless if you don't need it for long periods of time.
redwrench60
Well-known member
I have that exact same grinder. These were from the time when buying DeWalt meant something. Its so damn old the 6’ cord rotted off of it but it shows no signs of giving up, so I made a new cord from 14AWG SJOOW cable and made it 8’ while I was at it. It’s compact and powerful so It lives with a cut-off wheel installed. Wish I could buy an armload of NOS ones.Dewalt Corded tools from 30 years ago were industrial grade. I would have no issue using them.
Do you know which model they are?
I have an old one of these that I still use occasionally. Its a little noisy but running strong. Being able to thread the handle in either side or the top was a nice feature:
(As pictured in the ‘94 catalog)
zimman
Well-known member
Grinding *****. Always has. Tens of Thousands of hours grinding and I don't care if it's a Craftsman or a HF or a Milwaukee it still *****. LOL. Catch me on fire? Fine, keep grinding.
Flap wheels are wonderful and I hardly use a solid wheel anymore. Just no need unless I'm taking off more than a eighth of material.
Keep the old tools until they catch fire, then throw them. LMAO
Zim
This is my Craftsman I bought in 2005. While grinding inside a race car I cut the cord. It was exciting. Almost died. I redid the cord to just under 2' and it's still throwing sparks. These are not dentist tools. Keep them moving. LOL
Zim
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YesIHaveAHammer
Well-known member
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- Jun 1, 2025
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- 843
If the switch holds in the on position, as opposed to needing a trigger held down (dead man's switch), I'd upgrade on safety grounds.
Having been present many years ago when someone was using a grinder on the roof, something happened, minor cut to their hand, let go of the grinder and it slid down the roof and dropped down to the ground still on near other people. Not that a different switch is the whole solution to that, but it'd have helped.
Also auto brake as well as improving safety means you can put it down a few seconds earlier after use, don't need to wait for it to spin down.
Having been present many years ago when someone was using a grinder on the roof, something happened, minor cut to their hand, let go of the grinder and it slid down the roof and dropped down to the ground still on near other people. Not that a different switch is the whole solution to that, but it'd have helped.
Also auto brake as well as improving safety means you can put it down a few seconds earlier after use, don't need to wait for it to spin down.
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seber
Well-known member
I have Fein, Hilti, and a bunch of Metabos. I have discarded Milwaukees and one Dewalt for not holding up. The Hilti is by far the best of the lot. Fein and Metabo are both very good but the soft start feature on One of the Metabos is really nice.
That's what I have.Dewalt Corded tools from 30 years ago were industrial grade. I would have no issue using them.
Do you know which model they are?
I have an old one of these that I still use occasionally. Its a little noisy but running strong. Being able to thread the handle in either side or the top was a nice feature:
(As pictured in the ‘94 catalog)
I’ve never seen a pipeline truck or a fab shop around here with anything but DeWalt or Milwaukee, with occasional 9” Makita that won’t die.
dnschmidt
Well-known member
Likely because they are more readily available and cheaper. Here in Phoenix where all we have is HF, HD and Lowes finding Metabo requires you to go to a welding supply house. Back home in Pittsburgh where tools stores existed Metabo was the angle grinder king. Now you have to buy them through the Internet.
We have five welding supply houses in the next town over, but the nearest Home Depot or Lowe’s is an hour away….and yellow and red is still the order of the day.
e015475
Well-known member
Just bought a cordless Milwaukee M18 Fuel angle grinder, and so far I really like it. My drill and drivers use the same battery.
In the past, 99% of the time I'd use an air-powered die grinder instead of an angle grinder. They were so cheap I'd keep three or four in the drawer, straight and angles, with cutoff wheels or roloc discs already installed.
There's a 25 year old corded Makita angle grinder in a drawer in the shop that gets used a couple times a year along with a $15 HF grinder that still works after some pretty severe abuse (it is noisy and vibrates like crazy)
I think the smaller Milwaukee M18 grinder will be able to replace both the Makita and the air-powered die grinders for everday use - the corded ones will only come out occassionally when more grunt is needed.
I just finished grinding a boss off of an aluminum engine block with the Milwaukee and a 40-grit flap disc- much quicker and with more finesse than a die-grinder with a sanding disc or a carbide burr.
Flap discs work amazingly well
In the past, 99% of the time I'd use an air-powered die grinder instead of an angle grinder. They were so cheap I'd keep three or four in the drawer, straight and angles, with cutoff wheels or roloc discs already installed.
There's a 25 year old corded Makita angle grinder in a drawer in the shop that gets used a couple times a year along with a $15 HF grinder that still works after some pretty severe abuse (it is noisy and vibrates like crazy)
I think the smaller Milwaukee M18 grinder will be able to replace both the Makita and the air-powered die grinders for everday use - the corded ones will only come out occassionally when more grunt is needed.
I just finished grinding a boss off of an aluminum engine block with the Milwaukee and a 40-grit flap disc- much quicker and with more finesse than a die-grinder with a sanding disc or a carbide burr.
Flap discs work amazingly well
Corded grinders haven’t changed that much in 30yr…. It’s not like these are metal cased Black and Deckers from 1953. A yellow grinder from 1995 and a yellow grinder from 2025 look, act, and feel pretty much the same.
Folks act like a 4-1/2 grinder is the harbinger of death, and the epicenter of tool development.
nadogail
Well-known member
i have one Dewalt grinder, it was supplied by a former employee when my Harbor Freight grinder, which was the only grinder in the shop died.
All my grinder purchases since then have been Harbor Freight I buy them only when they are on sale.
All my grinder purchases since then have been Harbor Freight I buy them only when they are on sale.
chipdog4
Well-known member
Those are great grinders. I have 8 or 10 of the same in Black and Decker Professional series
seber
Well-known member
Pipeliner grinders are owned by the company and tend to disappear on a regular basis. They aren't llikely to spend money on Metabos.
IndyGarage
Well-known member
Yeah I'm with others. I own probably 15-20 angle grinders. I probably destroy 2-3 of them a year for the past 10 years.
I would say if you have a 30 year old DeWalt it's probably fine for most tasks and better than any of the cheap chinese ones. The Dewalt brand was the continuation of the Black and Decker Professional line - so they were good tools back then.
Almost any angle grinder is fine for just grinding. Where you will have problems is when you put a cutoff wheel or a wire brush on them. Both of those tasks require much more power and put more stress on the gearbox. it will burn up a cheap grinder quickly.
If you are buying a new one, I would recommend either the $40 porter cable - which isn't smooth but is indestructable or any mid to upper tier Makita - which are both smooth and indestructable.
I would say if you have a 30 year old DeWalt it's probably fine for most tasks and better than any of the cheap chinese ones. The Dewalt brand was the continuation of the Black and Decker Professional line - so they were good tools back then.
Almost any angle grinder is fine for just grinding. Where you will have problems is when you put a cutoff wheel or a wire brush on them. Both of those tasks require much more power and put more stress on the gearbox. it will burn up a cheap grinder quickly.
If you are buying a new one, I would recommend either the $40 porter cable - which isn't smooth but is indestructable or any mid to upper tier Makita - which are both smooth and indestructable.
Wamsutta
Well-known member
BOSCH 1375A from 30 years ago is the perfect 4-1/2 inch grinder in my opinion.
finn
Well-known member
They’re pretty much commodity tools at this point, at least for 90% of users.
I’m not sure about your part of the world, but pipeline welders here are self employed contractors. They supply everything but the pipe, from truck to boots.
They’ll spend $25k on a welder to put on a $90,000 pickup. If the more expensive grinders were worth it, they’d have them.
rlitman
Well-known member
They sure were. But a lot of the ageless brutishness of those good old tools is embodied in the $20 imports today.
I'd use a 30 year old Metabo without hesitation. I'm not too keen on stuff without an anti-kickback clutch at a bare minimum.
Paddle switches are ok in some situations, but a hindrance in others. They're not my cup of tea for the most part, though my favorite grinder (at the moment) happens to have one.
The only grinder mod that bothers me more than grinders without guards is paddle switches without their safety triggers. Nothing worse than a grinder that turns itself on when put down.