How to cut sheet metal evenly with an angle grinder

Plain cuts in thin sheet metal

Metal, 1 mm thick, is not too difficult to cut, but here you need to be extremely careful and accurate. It is when cutting such material that the disc often “bites”. First of all, you need to make sure that there are no defects on the cutting plane of the wheel. It is they who lead to the fact that the cut-off wheel flies.

sheet, metal, evenly, angle

DIY | Angle Grinder Cutting Jig | Straight Cut Sheet Metal

Thin sheet metal should be cut from the far edge, working backward

You should start from the far edge of the sheet, moving back. In this case, it turns out that the master pulls the angle grinder towards himself. In this case, the disc should not be immersed deeply. maximum 5-6 mm. With this method of cutting, it turns out that the cut-off wheel simply cannot catch on anything. If the disc goes deep, the area of ​​contact with the metal is sharply reduced. This leads to snags, as a result of which the cut-off wheel can fly apart.

Angle Grinder Safety

This question is the most important one. Indeed, if you violate the rules for operating an angle grinder, you can get serious, sometimes incompatible with life, injuries. Let’s consider the main ones that must be observed.

  • Disk size. Many people believe that if you put a large disc on a small angle grinder, after removing the protective cover, nothing bad will happen. Say, a large angle grinder is more powerful. This delusion is life threatening. The fact is that the speed of a small angle grinder is much higher, and therefore the discs for them need different ones. When installing a large disk, the master, most likely, will not even have time to start work. the disk will fly apart when turned on, which in the absence of a protective casing will lead to disastrous results.
  • Direction of rotation. Some “craftsmen” do not like the fact that sparks fly at their feet when they work. They unfold the hood, reposition the handle, and begin work. This is what most often leads to the fact that the disc scatters when caught on a sharp edge. The rotation of the disc during operation of the angle grinder should be carried out “towards itself” and not vice versa.
  • Personal protective equipment. Wear goggles or face shield, gloves, mask or respirator is necessary. This will save you from burns, eye injuries, which, unfortunately, with such work are not uncommon.

easy ways to cut sheet metal evenly with an angle grinder

Cutting sheet metal with a variety of tools may seem straightforward at first glance. Indeed, depending on its thickness and size, different methods should be used. It is clear that a sheet of any thickness can be cut with gas, but in this case, the edge will not work perfectly, additional processing will be required, and this is an unnecessary waste of time. How then to proceed? Today we will consider 3 easy ways to cut a metal sheet with an angle grinder so that the edges are even and not get injured.

How to cut a thicker sheet of metal with an angle grinder

Consider cutting 8mm sheet metal. It is best to move forward here. it is much more convenient that way. However, if you just pass the seam along the drawn mowing line, you will get flaws. you cannot make it perfectly even. At the same time, the tension on the hands increases. after all, you have to constantly monitor that the angle grinder does not go to the side. There is a very good way to avoid this.

When cutting thick metal, you need to move forward along the intended cut

At the place of the cut, a steel corner is laid, which is pressed against the sheet with clamps on both sides. In this case, the drawn line should be from its vertical part. Now you can walk along it several times, slightly touching the corner so that you get a groove with a depth of about 1-2 mm. After that, you can remove the corner and start normal cutting. It is the groove that will prevent the disc from leaving the intended trajectory, and the edge will turn out to be perfectly flat.

Working with a small angle grinder is even more dangerous than working with a large

How to cut a pipe straight with an angle grinder: normal perpendicular cutting at 90º, cutting a cylindrical pipe at an angle of 45º, how to use a paper template to mark a 45º cut, how to mark a 45º cut on a profile pipe. read the publication.

Another similar option

You can do it in another way. First, the same work is done as in the previous version. a strip is drawn, a corner is laid and pressed. But here the groove is made a little deeper. 4-5 mm. After the corner is removed, the rest of the metal can be simply broken off, and the edge can be processed using an angle grinder with a grinding disc. However, small pits on the edge are possible here, which makes the second option more acceptable.

The groove along the guide angle is made a little deeper than in the previous version

Summing up

The fact that the angle grinder is very convenient for cutting metal is not disputed. However, you must be able to work with it and strictly follow all safety precautions and regulations. You need to understand that they were created precisely in order to preserve the life and health of a master working with such a dangerous tool as an angle grinder.

We hope that everything we have told you today will be useful to those who have no experience with an angle grinder. If anything remains unclear, you just need to state it in the Комментарии и мнения владельцев below the article. HouseChief editors are happy to answer all questions as quickly and fully as possible. Do you have experience with similar work or do you know other cutting methods? Then we ask you to write about it in the discussions. Such information will be very useful to many. And finally, according to the already established good tradition, we invite you to watch a short but rather fascinating video on today’s topic.

Features of cutting aluminum on a guillotine

Using a guillotine, cutting aluminum sheet material.

The guillotine is a type of press-forging machine, and the machine can be operated manually, mechanically and hydraulically.

The operation of the mechanical guillotine is based on the use of a kinematic chain system, while the functioning of the hydraulic guillotine is due to the working fluid.

Manual guillotines easily cut thin sheets of aluminum, the installation is powered by a simple lever-spring mechanism.

Such guillotine shears are convenient for home use, as they are compact in size and do not require much installation space.

Mechanically controlled guillotines are powered by power supply.

Such devices perform cutting of aluminum and other metals with permissible deviations, therefore they cannot provide a perfectly accurate cut of the material.

High-precision cuts are possible using only hydraulic guillotines, they have an impressive design and an integrated back ruler, which contributes to the accuracy of the processes performed.

Modification of hydraulic guillotine installations, during which the existing engines were replaced with new, more powerful ones, allows cutting aluminum of any thickness.

Electric jigsaw

Before starting work, it is important to make sure that the file is fixed in the tool specifically for metal. Of course, a blade for wood will also cut aluminum, only the cut quality will leave much to be desired. The profile is cut from the back, then the side edges are cut in turn.

  • electrical equipment facilitates the user’s work;
  • quality close to ideal (there will be no burrs, bevels, or other defects on the product);
  • speed of work;
  • multiple use (with the right choice of a file);
  • jigsaw is cheaper than similar devices for cutting aluminum profiles.
  • the workpiece must be securely fixed so that it is not “led” when the jigsaw is in operation.

How to cut thin sheet metal evenly

To quickly and accurately perform work related to cutting sheet metal, you need to choose the right power tool such as an angle grinder. For cutting thick or thin sheets, you need to select an angle grinder of the appropriate power, as well as the diameter of the cutting wheel. In addition, when buying, it is recommended to pay attention to the functionality of the power tool (the presence of a soft start system, regulation of the rotational speed of the disk).

For everyday home, household use, when it becomes necessary to cut thin metal, ordinary low-power angle grinders (up to 1 kW) are suitable. However, in order to cut thick sheets, it is preferable to purchase a powerful angle grinder (from 2 kW), which are equipped with a soft start system. In total, there are several types of grinders, differing from each other both in scope and functionality. Such a power tool is:

How to use a Cutting Disc with an Angle Grinder

  • professional type;
  • semi-professional type;
  • household;
  • with one or more handles;
  • with the presence of a soft start system and a mechanism for self-regulation of revolutions.

In addition, there are angle grinders of medium, small and high power. Such a power tool can be used both for cutting metal and other hard surfaces (concrete, stone). Often an angle grinder is used to perform a variety of work related to cleaning, grinding, and polishing work surfaces.

For cutting sheets of small thickness, you can use a low-power angle grinder, the power of which is about 0.6-1 kW, with a disc diameter of 125 mm.

In order to accurately and evenly cut thin sheet metal, the thickness of which is about 1 mm, you need to be extremely careful and careful. Indeed, when processing such materials using an angle grinder, the cutting disc can “bite”. Therefore, before carrying out work, you should inspect the cutting blade and make sure that there are no defects and chips on its surface.

If the integrity of the disc is broken, then it is not recommended to use it to perform work on cutting products made of metal. Otherwise, the deformed or damaged wheel may fly apart during cutting.

In order to evenly cut thin sheet metal with an angle grinder, you need to draw a line on its surface along which the cut will be made. You should start cutting the sheet from its far edge, gradually moving back in the opposite direction. With this method, the user will pull the angle grinder in their direction, gradually moving along the sheet to its second edge.

Watch the disc while cutting the thin sheet. It should not be allowed to sink too deep into its surface during cutting. The maximum immersion depth should not exceed the 5-6 mm mark. This method of cutting eliminates the possibility of wheel snagging. Otherwise, when the depth of penetration of the cutting disc into the sheet exceeds the mark of 6 mm, due to the reduction in the contact area, there is a high probability of snagging.

What was the advice that helped to easily cut the aluminum tank?

And the advice was as follows. The cut must be lubricated. For example, used car oil will do just fine for this purpose. A little work off, and the work began to boil. The disc did not get stuck, the aluminum was cut with a bang. So, a simple trick from an experienced person helped save both nerves and strength. And perhaps health, as the angle grinder has ceased to get stuck in aluminum and try to escape from his hands. You yourself understand what such a situation threatens when working with this tool. Don’t believe me? Talk to surgeons, they will tell you.

Features of cutting aluminum with an angle grinder

High-precision cutting of soft metals is difficult with an angle grinder, especially aluminum. The material, which is viscous in its structure, causes difficulties in the process of work and requires the use of specific actions.

For example, to cut a sheet product or any aluminum billet with a large thickness, kerosene is dripped onto the working seam.

In this case, kerosene acts as a lubricant and does not allow the cut-off wheel of an angle grinder to get stuck in the metal.

When working with an angle grinder, it is necessary to strictly observe safety rules and monitor all the time so that a fire does not appear due to kerosene.

When purchasing a disc for an angle grinder, you need to know what material this wheel is intended for processing.

Otherwise, an incorrectly selected circle will not only fail to fulfill the task, but may cause unexpected injury.

Therefore, when choosing a cutting wheel for cutting aluminum, it is recommended to pay attention to its front surface.

It is on it that the manufacturer indicates what diameter the product has, what material the circle is intended for processing.

In addition, the cutting wheel for an angle grinder has a designation of the size of the bore, as well as an indication of the permissible number of revolutions, other marks on the features of operation.

It is very important in the process of working with an angle grinder not to forget that the wheel can only be influenced by radial force.

Plasma and laser machines

The best way in terms of quality and speed, but not suitable for home conditions. Plasma cutter and laser machine are considered professional equipment and are found in metallurgical enterprises. If there is an installation nearby and cutting an aluminum profile on it is possible, this should be used.

  • profile cutting takes a couple of minutes;
  • the user only sets up the equipment, the rest is done by the machine;
  • cut quality is the best of all methods.
  • ;
  • the inability to use at home or in the garage;
  • noise during operation.

Glass cutting

The angle grinder has no problem cutting glass. For this operation, you can use the cheapest ceramic wheel. A light contour cut is made and then deepened. The cut glass is laid out on the edge of the table and broken.

Cutting glass pipes with an angle grinder can be seen as an example of cutting a regular glass bottle. The bottle is placed in an open vise or placed between two wooden blocks. Turning it little by little, make a cut with an angle grinder. The bottle is rotated until the unnecessary part simply disappears.

Pipe cutting at an angle of 45 and 90 degrees

If you need to cut the pipe at an angle of 45 degrees, which is more often required when laying water, heating pipes. Steel, cast iron pipes that are cylindrical in shape are often used. In installation work, rectangular or shaped pipes are used. However, you should properly cut the pipe with an angle grinder, so that later it can be easily connected. Therefore, you should carefully mark the pipe.

Some craftsmen try to mark the place of the cut using a tape measure, but we warn you that the result is likely to be negative. And for a positive result, consider the following professional recommendation.

Take a sheet of paper or cardboard, preferably A4, fold it diagonally and wrap it around the pipe where you plan to cut it evenly. The edges of the paper should be exactly aligned with each other. And the side of the paper that is closer to the end of the pipe was perpendicular to the axis. Then mark the cut line in a circle.

If you need to cut exactly at an angle of 90 degrees, then solve the problem quickly using paper or masking tape again. Wrap around the pipe so the ends match. Make even lines and saw off.

Masters advise using a square when cutting a profile pipe. To do this, apply the square in turn to the sides, and turn and mark with smooth movements. After action, fix the pipe and cut. Prepare yourself a template that will come in handy in the future and save time. It is better to do the action with an angle grinder, so the cut will be smoother.

When working with a cast iron pipe, keep in mind that it is a brittle material. Therefore, we will point out a method with which it will be possible to cut such a metal without damage.

Before starting work, make notes for the cut, just like with steel pipes. Place a piece of wood for support. Run an angle grinder around the circumference of the pipe making small cuts. Then take the chisels, insert into the groove and hit hard with a hammer. Note that bakelite-based cutting discs are used to cut cast iron pipes.

If you do not have an angle grinder at hand to cut a cast-iron sewer pipe or other purposes, use a metal hacksaw, chisels or special pipe cutters.

Cutting a gas pipe is dangerous, so it is best to entrust it to professionals. But if you are confident in your strength, then to cut the metal, take an angle grinder, welding, hacksaw, gas welding.

  • Shut off the gas riser before work. Then release the rest of the gas from the pipe. To do this, set fire to the gas in the burners and wait for it to go out.
  • After the actions taken, cut. Using the welding method, the metal base burns out when exposed to high temperature. The result is fast and effective. But remember that cutting or rooting gas pipes again requires experience.

How to cut slate without an angle grinder

If there is no angle grinder, then you can cut the slate sheet using a regular hacksaw. Better for these works is a hacksaw with fine teeth and a small divorce. As a last resort, you can use a hacksaw blade from a hacksaw for metal, and just a knife.

The main thing is to correctly distribute the forces and load on the sheet in order to avoid chips and breakage of the slate. Wave slate is cut somewhat more difficult, and a sheet of flat sheet slate can be cut simply with any tool.

We cut paving slabs, tiled, porcelain stoneware

To cut paving slabs with an angle grinder, you will need a special diamond-cut wheel. Markings are made on the tile, and an incision is made along these markings to almost half the radius of the circle. If an angle grinder with a large circle, then in one pass you can cut the tile at once to the full depth. The main thing is that it should not be larger than the radius of the circle. If the radius of the circle is not enough, then the tile is turned over and a counter cut is made.

Tiles without chips are better processed with a stone cut-off wheel. A fishing line is applied to the tile, along which a contour cut is made. Then the depth gradually increases. When the cut part becomes larger, the tiles are placed on the edge of the table and broken along the mowing line. Irregularities and roughness can be earned later.

Porcelain stoneware works well with stone rounds. Cutting technology is no different from tile cutting technology.

How to cut straight with an angle grinder

How to properly saw or cut with an angle grinder

Different materials behave differently when machining with an angle grinder. Some immediately overheat and break, others are deformed, and still others do not want to be processed at all. It is difficult to know all the subtleties of working with an angle grinder, but practice requires you to know at least something.

How to cut a pipe straight with an angle grinder at 45 and 90 degrees | Cutting methods

When dealing with construction or plumbing tasks, you need to know how to cut the pipe straight with an angle grinder. In the article, we will consider quick and easy ways of how to properly cut a pipe with an angle grinder so that the result is perfect.

How to cut without dust

Any dust is harmful to human health. During repair or construction, it settles everywhere. It takes a long time to remove it afterwards, and it is rather difficult. But the main thing is that it cannot be removed from the body. In order to work without dust, you need to make a small and inexpensive attachment for an angle grinder.

This device is very similar to a medical drip. In an ordinary plastic bottle with a volume of 1.5. 2.0 liters, we start a tube from a dropper. We leave only the regulator on it. In the protective casing of the angle grinder, make a hole in the diameter of this tube. Insert another tube of the same kind into this hole.

We connect these two tubes, pour water into the bottle and open its supply to the circle. After the first rough cut, we adjust the water supply, which should extinguish all dust released during cutting.

With such a device, it is possible to process concrete, brick and many other materials that, when destroyed, emit a large amount of dust.

Like all other tools, angle grinders are divided into classes, professional and household tools, as well as by their design features.

This is perhaps the most widely used tool besides the drill. Many people work with an angle grinder, but not everyone is wondering about the correctness of the manipulations performed, from the point of view of personal safety and quality of work. In this article, we want to devote you to the basic subtleties of working with this tool and consider in detail the following questions:

Before you get started, you need to prepare your angle grinder. We mean the choice of rig (disc). The following points should be considered here:

  • Disc diameter. Remember, the smaller the diameter of the disc, the more revolutions (higher rotational speed) it can withstand, and vice versa.
  • The choice of disc depends, first of all, on the material with which you plan to work and the design features of your instrument.
  • Pay close attention to the legend and markings on the disc. Having carefully studied them, you will understand whether the selected equipment is suitable for the proposed work.

Also, always follow safety precautions and wear special equipment such as gloves, goggles, long sleeved robes and closed shoes.

First of all, clear the workplace of unnecessary items. Securely fix the workpiece to be processed, having previously marked it on it, if necessary. Getting started.

Always hold the tool firmly and confidently with both hands. Take a steady body position. You need to stand so that sparks, in the process of work, do not fly onto clothes, and even more so in the face.

Always remember about such a thing as kickback. This is the most dangerous thing that can happen when working with a grinder. It can happen if the disc is strongly jammed in the workpiece. In such a situation, the angle grinder will be thrown back sharply. Monitor the process to avoid this.

Also remember that the power cord of the angle grinder must be isolated from sparks during operation. If you need to move the instrument to a different work surface, be sure to turn it off first, then unplug the power cord. The same should be done in the event of a power outage. As soon as the power goes out, turn off the instrument and then unplug it from the mains. If this is not done, then when power is restored, the angle grinder will start to work in a chaotic mode again and can cause irreparable harm to your health, others or damage objects around.

The most frequently asked question that arises among novice craftsmen is the following: How to cut with an angle grinder correctly: towards yourself or away from yourself? Many do not betray this special significance, but in vain.

Bulgarian manufacturers advise their consumers the following: You need to work with the tool in such a way that the stroke (direction) of the cut coincides with the direction of rotation of the disc.

Experienced craftsmen have a clear answer to this question: You need to make a cut from yourself. This is for your safety. If the angle grinder is pulled out of your hands, the tool will be thrown in the opposite direction from you. If you cut in the direction of yourself, when the above situation occurs, the tool will fly to your feet. We will not describe the consequences. You can imagine them yourself.

If you are cutting parts or workpieces that have thick metal, cut them in an extremely straight line.

When working on a part such as a corner or cutting a profile or shaped tube, which is usually quite long, cut the overhanging edge. Otherwise, if you make a cut in the place between the supports, an outcome such as a jamming of the disc due to the deflection of the workpiece is possible.

If you are cutting a corrugated sheet (sheet metal sheeting), metal siding (metal siding) or metal tiles, take care of the presence of special anti-corrosion substances that need to be lubricated in order to avoid sudden corrosion.

In case you are cutting paving slabs or paving stones, get a special diamond cut disc.

Reinforced concrete, concrete and other similar materials must be processed with special discs for stone.

If you need to cut a gas or oxygen cylinder, be very careful as it may explode due to the remaining trace of gas or condensation. It is better not to carry out such work at home.

If you need to cut glass or, for example, a mirror. the most trivial ceramic disc will suit you.

When working with material such as wave slate, do not apply extra effort to avoid chipping and unevenness.

It is possible to process rubber with an angle grinder, but not necessary. If you understand what we mean.

Grooves, springs, rebar or channel can also be cut with an angle grinder.

Need to cut drywall or polycarbonate? Do this very carefully to avoid chipping and breaking the material. You will need neatness if you need to cut glass mosaics. For example, if you are cutting off excess parts from a pasted arch, cover the cut and the part to be cut with masking tape or construction tape. This minimizes the possibility of cracks and prevents debris from scattering on the floor after cutting.

How I Make Straight Accurate Cuts With The Angle Grinder


As we said above, the range of applications for the angle grinder is incredibly wide. She also acts as an excellent helper when cutting material such as tiles or tiles. But, a logical question arises regarding the equipment: How is it better to work on tiles? To carry out this type of work, you need to get a grinding diamond wheel and a tile holder. It is hardly possible to work without dust with this material, so take care of a protective mask in advance.

Let’s take a closer look at the process itself and methods of cutting tiles or tiles without chips.

  • The easiest way is to cut straight. Fix the tile well so that its edge remains suspended along the mowing line of the cut and get to work.
  • The next method to be noted is cutting at a 45 angle. This method is more complicated than the first one. First, we cut the ceramic tiles with a straight cut. Then, when cutting, we direct the disc of the angle grinder at an angle and remove the unnecessary part. Next, we grind the cut with sandpaper.

To begin with, let’s talk about the dangers that lie in wait for the master when cutting metal with an angle grinder, namely:

  • Fragments of the disc, in the event of a fracture;
  • Powerful stream of sparks and small abrasive particles;
  • In some cases, the inability to hold the instrument in the hands.

Now, a few tips for working with metal.

If you have no experience in this type of work, then, for a start, it is worth practicing on unnecessary details. If in the process of work, you decide to change the cutting plane when the disc is inside the workpiece, this will immediately lead to its breakage.

To increase the service life of discs, especially expensive ones, they need to be cooled. This is done with water. It is necessary to water the cutting area. It is advisable that you work with a partner who will carry out all these additional manipulations.

Also, breaks of 5-7 minutes every 20-30 minutes of work will help to increase the service life of the equipment, and the tool itself. This rule is especially important when working with household grinders. This way you will protect your instrument from overheating.

You should also remember that you should not put pressure on the angle grinder during operation, otherwise it may fail due to overheating, or the disc will jam. If you feel that performance is too slow, try changing the drive.

Many experienced craftsmen claim that cutting wood with an angle grinder is to be. Our opinion: indeed, it is possible to cut wood with an angle grinder, but it is extremely unsafe, inconvenient, slow and of poor quality. And that’s why.

Firstly, during operation, the disc of an angle grinder gets very hot and becomes incredibly fragile. The slightest misalignment may result in a ruptured disc. You can find out about the consequences of this situation from the pictures on the Internet.

Secondly, when working with a disc equipped with victorious solders, these solders can easily end up under the skin. And this is a direct way to the hospital, because it will not be possible to extract them on your own, plus all this is fraught with infection.

Thirdly, when using a disc on wood, the teeth can grab more wood than you expect, and this, in turn, will lead to that. that the angle grinder will simply rip out of your hands. It is very dangerous!

We hope we have explained in an accessible way why you cannot use an angle grinder when working on wood and you will not even try.

But, as practice shows, many craftsmen at home resort to using an angle grinder when processing materials such as chipboard, laminated chipboard, laminate, OSB board or plywood. This should be cut as carefully as possible and in compliance with all safety measures. Otherwise, you can not only spoil the material, but also be injured.

In order not to spoil the workpiece and make a high-quality smooth cut with an angle grinder, you will need to perform a number of preparatory measures, which we will discuss in this part of the article.

  • Markup. All ingenious is simple. first we mark, then we cut. Take pipe cutting as an example. First, use a chalk or marker to apply the size, then use paper or duct tape. The main thing is that the edge is even. We take the selected auxiliary material and carefully wrap it around the pipe. Its border will be a clear and accurate marking of the cut. When performing work, it is important to remember that under no circumstances should you change the position of the tool stroke. Otherwise, the disc may jam or break. Also, do not put additional pressure on the tool, as this will immediately be reflected in the curvature of the cut and spoil your workpiece.
  • It is very important to choose the right thickness of the circle. There is a simple axiom at work: the thicker the material you are working with, the thicker the disc should be. When choosing tooling, consult an expert in the field and pay attention to the marking of the grinding wheel applied to his shirt.

Working with an angle grinder is a business that requires constant attention and control, because the consequences of accidents are irreversible. Therefore, before starting work, take care of the following:

  • Take care of the protection of all parts of the body: face, hands, eyes.
  • Clean the workspace from excess, especially the place where the sparks fly out, remove all combustible materials away.
  • The workpiece to be machined must always be securely clamped.
  • Be sure to install the protective cover.
  • Hold the tool firmly while working.
  • At the end of the work, wait until the rotation of the blade has stopped completely, place the angle grinder with the disc upwards so as not to damage it, unplug the tool from the mains and make sure there is no smoke or signs of fire.


The list below shows the materials you can work with your angle grinder. It is forbidden to work with materials that are not on the list.

  • The angle grinder is perfect for cutting materials such as cast iron, metal, steel, copper, aluminum, iron, titanium. You can cut stainless steel or galvanized.
  • With the appropriate attachments, you can also work with plastic, ceramics, glass, plexiglass and porcelain.
  • Stone, granite, marble, asphalt, concrete or a wall made of it, brick, porcelain stoneware can also be processed with an angle grinder.

an angle grinder is useful if you need to cut water pipes or old heating.

One of the main factors that guarantee the quality of work is the right tooling. If you have any questions or want to purchase discs, please contact our managers at the specified phones. They will recommend suitable discs and advise you on all questions of interest.