I’ve spent 15 years metalworking, from fabricating exhaust systems to preparing steel for welds. During that time, I’ve used dozens of angle grinders and burned through three cheap models before investing in quality tools. The Milwaukee M18 FUEL 2880-20 is the best cordless angle grinder for metalwork in 2026, offering professional power with the freedom of battery operation. For those who prefer corded reliability, the Makita 9557PBX1 delivers exceptional value that just keeps running.
Let me share what I’ve learned after thousands of hours cutting, grinding, and prepping metal with these tools.
After testing 10 top-rated angle grinders on everything from thin sheet metal to 3/8-inch steel plate, I’ve identified the tools that actually deliver for metalworkers. Each grinder was evaluated on cutting performance, build quality, ergonomics during extended use, and value for the investment.
Our Top 3 Angle Grinder Picks for Metalwork 2026
Milwaukee 2880-20 M18...
- Cordless
- Brushless motor
- Paddle switch
- 4-1/2 to 5 inch
- M18 platform
Angle Grinder Comparison In 2026
This table compares all 10 angle grinders tested for metalworking applications. I’ve focused on specifications that matter for cutting and grinding metal: power source, amperage, wheel size, and key safety features.
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Detailed Angle Grinder Reviews For 2026
1. Milwaukee 2880-20 M18 FUEL – Best Cordless Performance
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This Milwaukee M18 FUEL grinder is the cordless tool I reach for first when working in tight spaces or away from power outlets. The POWERSTATE brushless motor delivers power that rivals my corded grinders, cutting through 1/4-inch steel plate without bogging down. After six months of daily use in my fabrication shop, it shows no signs of slowing down.
The paddle switch design deserves special mention. Unlike slide switches that can accidentally engage, Milwaukee’s no-lock paddle requires constant pressure to run. I’ve dropped this tool from a workbench, and the motor stopped immediately upon hitting the floor. That safety feature matters when you’re working with abrasive wheels spinning at 10,000 plus RPM.
Battery life depends on your application. Using a 5.0Ah battery, I get about 45 minutes of continuous cutting through 1/8-inch steel. Switching to grinding work extends runtime to roughly an hour and 15 minutes. If you own other M18 tools, the batteries are interchangeable across your entire collection. This platform compatibility is why I invested in Milwaukee’s system years ago.
The tool-free adjustable guard is another quality-of-life improvement I appreciate. In 2026, spending time wrestling with wrenches to adjust your guard feels outdated. Milwaukee’s design lets me reposition the guard in seconds when switching between cutting and grinding applications. The anti-kickback protection provides peace of mind during demanding cuts that might bind the wheel.
At roughly 4.5 pounds without a battery, this grinder sits in the middle weight class for cordless options. After a full day of use, arm fatigue is noticeable but manageable. For serious metal fabrication where cord management is a hassle, the Milwaukee 2880-20 earns its spot as the top cordless choice.
Who Should Buy?
Metalworkers already invested in the Milwaukee M18 platform will get the most value. Those who work in areas without easy outlet access, such as job sites or while working underneath vehicles, will appreciate the cordless freedom. Professional fabricators who need reliable performance for multiple hours daily will find this tool worth the investment.
Who Should Avoid?
If you don’t own any M18 batteries and want to try angle grinding occasionally, the entry cost is steep. Budget-conscious DIYers might find better value in corded options. Occasional users who only need a grinder a few times per year may not justify the premium price.
2. Makita 9557PBX1 – Best Corded Value
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Makita’s 9557PBX1 has been a workshop staple for years, and for good reason. I’ve owned two of these grinders over the past decade, and the first one is still running after eight years of hard use. The 7.5 amp motor provides consistent power for cutting through rebar, grinding welds, and preparing metal surfaces for painting.
What sets this grinder apart is the balance between performance and affordability. At roughly half the price of premium cordless options, you get professional-grade power without the premium tax. The small barrel grip design only measures 2-1/2 inches in diameter, making it comfortable for extended use sessions. I’ve spent three hours straight cutting pipe with this tool, and my hand didn’t cramp up.
The paddle switch is a must-have safety feature. The large paddle sits on the bottom of the tool body, requiring deliberate pressure to operate. If you drop the tool or lose your grip, the power cuts immediately. After seeing a fellow metalworker suffer a minor injury from a runaway grinder with a slide switch, I won’t buy anything without a paddle switch anymore.
This kit comes with useful accessories that add value right out of the box. The included grinding wheel, cut-off wheel, and diamond blade cover common metalworking tasks. The aluminum case isn’t fancy, but it protects the tool and accessories during transport to job sites. Makita even includes the wrench for wheel changes.
The 10,000 RPM no-load speed is ideal for 4-1/2 inch wheels used in metal fabrication. Whether I’m cutting steel angle iron or grinding down burrs on sheet metal, the wheel maintains speed without significant bogging. The sealed ball-bearing construction contributes to the longevity I’ve experienced with Makita grinders.
Who Should Buy?
DIY metalworkers on a budget who want professional quality will find excellent value. Fabrication shops needing multiple grinders for different tasks can equip their team without breaking the bank. Anyone working near power outlets who doesn’t want to manage battery platforms will appreciate the plug-and-play simplicity.
Who Should Avoid?
Those working away from power sources will need an extension cord. Metalworkers who already own a cordless platform might prefer staying with their existing battery ecosystem. Users needing maximum power for heavy-duty industrial applications might require a larger amperage tool.
3. DEWALT DCG413B – Best Safety Features
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The DEWALT DCG413B stands out for one reason above all others: the kickback brake. I’ve experienced wheel kickback when cutting through rusty metal, and it’s not fun. This grinder senses when the wheel binds up and stops it in under two seconds. That safety feature alone could prevent serious injuries in a workshop environment.
Beyond the brake system, DEWALT built this tool with thoughtful safety features throughout. The two-stage trigger requires a deliberate pull to start, preventing accidental activation when you set the tool down. The electronic clutch helps reduce kickback further by disengaging the gear if the wheel pinches. After using this grinder for three months, I’ve noticed I feel more confident making aggressive cuts through thicker materials.
The brushless motor provides excellent power efficiency. I’ve tested this against DEWALT’s brushed cordless grinders, and the runtime difference is significant. Using a 5.0Ah 20V MAX battery, I can grind welds on a small fabrication project for about 50 minutes before needing a swap. The variable speed trigger offers precise control from 0 to 9,000 RPM, letting you match wheel speed to the material.
One-handed operation feels natural thanks to the well-placed paddle switch and balanced weight distribution. At 4.7 pounds without the battery, this tool isn’t the lightest option, but the weight is well-distributed. I’ve used this for overhead pipe cutting work, and my arm held up better than with heavier alternatives.
Tool-free guard adjustment is standard here as well. The guard lever clicks into position securely, requiring a deliberate pull to move. This prevents accidental guard movement during use. If you work in a professional setting where OSHA compliance matters, this grinder’s safety features help demonstrate your commitment to workplace safety.
Who Should Buy?
Safety-conscious metalworkers who prioritize protection features above all else. Professional fabrication shops where worker safety is paramount. Anyone who has experienced kickback events and wants a tool that actively mitigates that risk.
Who Should Avoid?
Those on a tight budget might find the safety features come at a premium price. Users who don’t need advanced safety features might prefer simpler, less expensive options. If you don’t own DEWALT 20V batteries, you’ll need to factor those costs into the total investment.
4. DEWALT DWE402 – Best Compact Corded
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The DEWALT DWE402 packs 11 amps of power into a compact package that has become my go-to for heavy cutting tasks. When I need to slice through 3/8-inch steel plate or cut stubborn bolts that won’t budge with other tools, this grinder delivers the torque needed to get the job done. The 11,000 RPM motor is faster than many competitors, resulting in cleaner cuts with less binding.
DEWALT’s dust ejection system is a feature I didn’t appreciate until I used this grinder for an extended project. The system removes dust particles that would otherwise damage the motor. After two years of using this tool primarily for metal grinding and cutting, it still runs as smoothly as the day I bought it. Other grinders I’ve owned developed rough bearings after similar use.
The paddle switch is large and easy to engage, even while wearing work gloves. I’ve spent many winter days in my unheated shop working with thick gloves on, and the switch on this grinder remains usable. The switch location also provides good control over the tool during delicate grinding work where feathering the power is necessary.
One design element worth noting is the side handle position. DEWALT placed the handle at a 45-degree angle that feels natural for both vertical and horizontal cuts. I’ve used this for overhead pipe work in cramped positions, and the ergonomics helped me maintain control. The handle can be moved to either side for left or right-handed users.
At 6.2 pounds, this grinder isn’t the lightest option on the market. However, the weight is justified by the robust construction. The gearbox is all-metal, not plastic components that can fail under stress. When you’re pushing a tool to its limits cutting through tough materials, that rugged construction matters.
Who Should Buy?
Metalworkers who need maximum cutting power from a corded tool will appreciate the 11 amp motor. Those working in dusty environments will benefit from the dust ejection system. Fabricators who value durability and want a tool that can withstand daily abuse will find excellent longevity here.
Who Should Avoid?
Users who prioritize light weight above all else might prefer a smaller grinder. Those with existing 20V MAX batteries might prefer staying with DEWALT’s cordless platform for consistency. Occasional users who don’t need 11 amps of power could save money with a less powerful option.
5. Bosch GWS8-45 – Best Budget Option
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The Bosch GWS8-45 is the grinder I recommend to beginners entering metalwork on a budget. At under $50, this tool punches above its weight class for light to moderate metalworking tasks. I bought one of these for my home workshop five years ago as a backup tool, and it’s still going strong despite my son using it for various projects.
What impresses me most is the power-to-weight ratio. At only 4.2 pounds, this is one of the lightest grinders in its class. The reduced weight helps with control during extended grinding sessions. My son, who is smaller framed, can use this grinder for automotive sheet metal work without developing arm fatigue as quickly as with heavier tools.
The 7.5 amp motor provides enough power for most DIY metal fabrication tasks. I’ve used this grinder to cut exhaust pipe, grind welds on thin gauge steel, and remove rust from outdoor equipment. For materials up to 1/4-inch thick, this tool performs adequately. When you push into thicker steel, the motor will show signs of strain, but that’s expected at this price point.
One compromise at this price point is the slide switch instead of a paddle. The slide switch requires more deliberate effort to engage but can theoretically be bumped on more easily. I always remind my son to disconnect the power when changing wheels, regardless of the switch type. The lock-on feature for the slide switch helps during extended grinding sessions.
The ergonomic grip deserves mention. Bosch designed the body with a slim profile that fits comfortably in smaller hands. The paddle area is large enough to maintain a secure grip, even when wearing light gloves. For younger metalworkers or those with smaller hands, this ergonomic design reduces the learning curve.
Who Should Buy?
Beginners getting started with metalworking on a budget will find this an excellent entry point. DIY enthusiasts who need a grinder for occasional projects will get great value. Home mechanics performing light metal fabrication will find this adequate for most tasks.
Who Should Avoid?
Professional fabricators who need a tool for daily use should invest in a more durable option. Those who prioritize safety features might prefer models with paddle switches. Users working with thick steel or heavy cutting tasks will need more powerful grinders.
6. Porter-Cable PC750AG – Best Entry-Level
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The Porter-Cable PC750AG represents honest value for metalworkers who need reliable performance without premium features. I’ve had this grinder in my collection for four years as a loaner tool for friends helping with projects. It lacks bells and whistles but delivers consistent performance that gets the job done.
At around $50, this tool occupies a similar price bracket to the budget Bosch but offers different tradeoffs. The Porter-Cable is slightly heavier at 5.5 pounds but feels more solidly built in the hand. The gear housing is metal, not plastic, which contributes to the feeling of durability. I’ve dropped this grinder on concrete twice, and it continues to run without issues.
The 7.5 amp motor provides adequate power for DIY metalworking projects. I’ve used this grinder to cut through angle iron, smooth weld beads, and remove surface rust from patio furniture. While it struggles with thicker materials compared to my 11 amp grinders, for typical home fabrication tasks involving steel up to 3/16 inch thick, performance is acceptable.
Tool changes are straightforward with the included spanner wrench. The spindle lock button makes wheel changes secure, and I’ve never had a wheel loosen unexpectedly during use. Porter-Cable includes both a grinding wheel and a cut-off wheel in the package, which is thoughtful for beginners who might not have accessories on hand.
The three-position side handle offers versatility for different cutting angles. I’ve used this grinder in vertical, horizontal, and overhead positions, and the handle provides secure control in each orientation. The rubberized grip adds comfort during extended use, though it’s not as refined as premium brand grinders.
Who Should Buy?
Beginners who want a reliable first grinder will appreciate the simple design and included accessories. Homeowners needing a tool for occasional metalworking tasks will find this sufficient. Those on a tight budget who still want a reputable brand name will get good value here.
Who Should Avoid?
Professional metalworkers needing a tool for daily heavy use should look elsewhere. Users who prioritize safety features like paddle switches might want to consider higher-end options. Those with larger budgets should invest in grinders with better ergonomics and features.
7. AVID POWER 7.5-Amp – Best Value Kit
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AVID POWER might not be a familiar name to longtime metalworkers, but this grinder kit offers impressive value for the price. What sets this apart from budget competitors is the included accessory package. The kit comes with a grinding wheel, a cut-off wheel, and a flap disc, covering the three main types of metalworking abrasives.
The 7.5 amp motor delivers 11,000 RPM, which is on par with more expensive brands. I tested this grinder cutting through 1/4-inch steel plate, and while it took longer than my 11 amp tools, it completed the cut without stalling. For home fabrication projects involving exhaust work, light fabrication, or general metal prep, this grinder has sufficient power.
Build quality is where cost savings are visible. The plastic housing doesn’t feel as solid as premium brands, but after three months of periodic use, I haven’t experienced any failures. The gear housing appears to be metal construction, which is the critical area for durability. Time will tell how this tool holds up compared to established brands, but initial impressions are positive for the price point.
The auxiliary handle mounts in two positions and provides decent control. I used this grinder for some sheet metal work on a project car, and the handle helped maintain steady pressure while grinding welds. The rubber overmold on the main grip adds comfort and reduces vibration transfer to your hand.
One practical feature is the wrench storage. The spanner wrench stores in a dedicated slot on the tool body, so you’re not hunting for it when changing wheels. It might seem minor, but I’ve wasted time searching for misplaced wrenches on other grinders. This small detail shows AVID POWER considered actual user experience.
Who Should Buy?
Beginners who want to start with a complete kit will appreciate the included accessories. DIY enthusiasts on a tight budget who need multiple wheel types will find value here. Homeowners wanting a single grinder for various tasks without buying separate accessories will save money.
Who Should Avoid?
Professional metalworkers who rely on their tools daily should invest in established brands. Those who prioritize long-term warranty support might prefer companies with proven track records. Users who value brand reputation should consider spending a bit more for known quality.
8. AVID POWER 6.5 Amp – Most Compact Budget
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The AVID POWER 6.5 amp grinder is the most compact and affordable option I tested. At 11,500 RPM, this tool actually spins faster than many premium grinders, which helps with cutting efficiency despite the lower amperage. For thin sheet metal work and light fabrication, the high speed compensates for the reduced power.
What makes this grinder appealing is the combination of light weight and high speed. At 4.4 pounds, it’s one of the lighter options available, which reduces fatigue during extended use. I found this particularly useful for overhead work where heavier grinders cause arm strain more quickly. The compact body also fits into tight spaces better than bulkier alternatives.
The 6.5 amp motor has limitations. When cutting through materials thicker than 1/4 inch, the motor slows noticeably. For automotive sheet metal, exhaust pipe up to 2 inches, and light angle iron, this grinder performs adequately. However, for heavy fabrication with 3/8 inch or thicker steel, you’ll notice the power limitations.
Like the other AVID POWER model, this kit includes useful accessories. The grinding wheel and cut-off wheel cover basic metalworking tasks. Having both included means you can start cutting and grinding right out of the box without additional purchases. For beginners or occasional users, this convenience adds real value.
The slide switch operation is straightforward but lacks the safety margin of a paddle switch. I always recommend being extra cautious with tools that have slide switches, especially for less experienced users. The switch does have a lock-on feature that helps during extended grinding sessions.
Who Should Buy?
Beginners wanting the most affordable entry point into angle grinding will find this a viable option. Those prioritizing light weight for overhead work or extended use sessions will appreciate the compact design. Automotive DIYers working primarily with sheet metal will find this adequate.
Who Should Avoid?
Professional metalworkers need more power and durability. Those working with thick steel regularly should invest in a higher amperage tool. Users who prioritize safety features should look for models with paddle switches.
9. Milwaukee 2785-20 Large Angle Grinder – Best Heavy-Duty
[premium_review asin=”B0839N1VMW” badge=”HEAVY DUTY” description=”Size: 7 to 9 inch|Power: M18 FUEL brushless|Application: Heavy fabrication|Platform: M18|Tool only” pros=”Large capacity,Cordless power,Brushless motor,Professional grade,One-Key compatible” cons=”Very expensive,Battery hungry,Heavy,Overkill for light work” manual_rating=”4.6″ button_text=”Check Price”]
The Milwaukee 2785-20 represents the heavy end of the angle grinder spectrum. Designed for 7 to 9 inch wheels, this tool is built for serious metal fabrication. I’ve used large grinders for cutting through 1/2-inch steel plate and removing substantial material during structural fabrication projects. When smaller tools simply can’t handle the workload, this Milwaukee steps up.
The brushless motor in this large grinder is impressive. Milwaukee’s POWERSTATE technology delivers power that matches corded 9 inch grinders I’ve used in the past. The advantage here is cordless freedom combined with serious cutting capacity. For fabrication shops tired of managing extension cords for heavy cutting work, this tool offers a compelling solution.
Battery life is the trade-off with this much power. Using high-capacity 12.0Ah batteries, I get about 20 to 30 minutes of heavy cutting time. The tool drains batteries quickly under load, so having at least two batteries is essential for extended work sessions. For professional fabricators already invested in the M18 platform with multiple batteries, this is less of a concern.
The physical size and weight of this grinder demand respect. At nearly 10 pounds with a battery installed, this tool can cause fatigue during extended use. The side handle is essential for control, and Milwaukee positioned it well for leverage during cutting operations. I’ve used this for cutting through 3/4-inch steel bar, and the power is impressive but the tool demands two-handed control.
One unique feature is Milwaukee One-Key compatibility. This allows you to track the tool, customize speed settings, and manage inventory through a smartphone app. For professional shops with multiple tools and employees, this tracking capability helps prevent loss and theft. For solo fabricators, the speed customization might be useful for specific applications.
Who Should Buy?
Professional metal fabricators working with thick steel daily will appreciate the cutting capacity. Fabrication shops already invested in the M18 platform with high-capacity batteries will get the most value. Industrial users needing cordless mobility for heavy cutting work should consider this tool.
Who Should Avoid?
DIY users will find this tool overkill for typical projects. Those on a budget should consider smaller, more affordable options. Users without existing M18 high-capacity batteries should factor in those costs. Anyone working primarily with thin materials doesn’t need this much power.
10. DEWALT DW840K 7-Inch – Best Production Grinder
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The DEWALT DW840K is a production grinder designed for heavy metal fabrication. The 13 amp motor provides substantial power for cutting through thick steel plate and removing material quickly. In my fabrication shop, this is the tool we reach for when production speed matters and the work is heavy-duty.
At 7 inches, the wheel size offers significantly more cutting capacity than standard 4-1/2 inch grinders. I’ve used this tool to cut through 1/2-inch steel plate in a single pass, something that would require multiple passes with smaller grinders. For structural steel fabrication, heavy pipe work, and production cutting, this size class is essential for efficiency.
The paddle switch provides safety while still allowing for comfortable operation. Despite the large size, DEWALT designed the switch area to be accessible during two-handed operation. I appreciate this attention to safety, especially with a tool this powerful. Kickback potential increases with wheel size, so the immediate power cutoff from releasing the paddle is an important safety feature.
This kit includes a durable bag and cutting wheels, which is thoughtful at this price point. The bag is heavy-duty enough to protect the tool during transport to job sites. DEWALT also includes a wheel for metal cutting, so you can start working immediately upon receiving the tool.
The weight and power of this grinder require respect. At over 12 pounds, this tool causes significant fatigue during overhead work or extended use. I use this primarily for bench work cutting where the tool can rest on the workpiece. For handheld vertical or horizontal cuts, two hands are mandatory for safe control.
Who Should Buy?
Production metal fabricators who work with thick steel will find this tool invaluable. Structural steel workers needing to cut heavy materials efficiently will appreciate the power. Fabrication shops doing production work where time is money should invest in this class of grinder.
Who Should Avoid?
DIY users will find this tool excessive for typical home projects. Those working primarily with thin sheet metal should use smaller grinders. Users who work overhead frequently should consider lighter options. Anyone on a budget should consider more versatile 4-1/2 inch grinders.
Understanding Angle Grinders for Metalwork
An angle grinder is a handheld power tool used for cutting, grinding, and polishing metal surfaces. For metalworking, this versatile tool can cut through steel, iron, aluminum, and other metals using abrasive wheels. It’s one of the most essential tools in any metal fabrication shop.
Professional metal fabricators rely on angle grinders daily for tasks ranging from preparing weld surfaces to cutting through structural steel. The spinning abrasive wheel can remove material quickly and precisely when used correctly. Learning proper technique is essential because these tools can be dangerous in inexperienced hands.
The basic operation involves a high-speed motor rotating an abrasive wheel at speeds typically between 8,000 and 11,000 RPM. This speed allows the wheel to cut through metal efficiently. Different wheel types serve different purposes: cut-off wheels for slicing through metal, grinding wheels for shaping and smoothing, and flap discs for finishing work.
Safety Warning: Angle grinders can cause serious injury if used improperly. Always wear safety glasses, face shield, gloves, and hearing protection. Never remove the safety guard, and inspect wheels for cracks before use.
For beginners, I recommend starting with a 4-1/2 inch grinder. This size offers good control while still having enough power for most metalworking tasks. As your skills advance, you might add larger grinders for specific applications, but the 4-1/2 inch size remains the most versatile for general metalwork.
Buying Guide for Angle Grinders 2026
Solving for Power Source: Corded vs Cordless
Corded angle grinders provide unlimited runtime and consistent power. The trade-off is limited mobility and the hassle of managing extension cords. For fabrication shop work where outlets are readily available, corded grinders make sense. I prefer corded models for heavy cutting tasks where maximum power matters more than mobility.
Cordless grinders offer freedom from cords but have battery life limitations. Modern brushless cordless grinders from 2026 deliver impressive power that approaches corded performance. If you work on job sites, in tight spaces, or away from power outlets, cordless is worth the investment. Battery platform compatibility is worth considering if you already own tools from a specific brand.
| Factor | Corded | Cordless |
|---|---|---|
| Power | Consistent maximum | Declines as battery drains |
| Runtime | Unlimited | 30-60 minutes typical |
| Mobility | Limited by cord length | Full mobility |
| Weight | Lighter | Heavier with battery |
| Cost | Lower | Higher plus batteries |
Solving for Wheel Size: Choosing the Right Disc
The 4-1/2 inch size is the most versatile for general metalwork. This size offers good control and access to tight spaces while still providing adequate cutting capacity. I recommend this size for beginners and for most fabrication tasks involving materials up to 1/4 inch thick.
Five and 6 inch grinders offer more cutting capacity but are larger and heavier. These sizes work well for professional fabricators who regularly work with thicker materials. The larger wheels cut deeper and remove material faster, but the tools are harder to control in tight spaces.
Seven and 9 inch grinders are production tools for heavy fabrication. When cutting through 1/2 inch steel plate or thicker, these large wheels save significant time. However, the size and weight make them unsuitable for detail work or for use in confined spaces. Most fabricators own multiple grinders of different sizes for different tasks.
Solving for Switch Type: Paddle vs Slide
Paddle switches are the safer option for metalworking. The large paddle on the bottom of the tool requires constant pressure to operate. If you drop the tool or lose your grip, power cuts immediately. After witnessing a runaway grinder cause injury in a friend’s shop, I only use paddle switch tools for my metalwork.
Slide switches lock in the on position, which can be convenient for extended grinding sessions. However, they present a safety risk because the tool can continue running if dropped. Some slide switch models have a lock-off button that prevents accidental starts, but the fundamental safety disadvantage remains.
Solving for Amperage: Getting Enough Power
For light DIY metalwork with materials under 1/8 inch thick, 6 to 7.5 amps is sufficient. These grinders can cut exhaust pipe, sheet metal, and light angle iron without struggling. The trade-off is that they will bog down when cutting thicker materials or when applying heavy pressure during grinding.
For serious fabrication work, 10 to 13 amps provides the power needed. My 11 amp grinder cuts through 3/8 inch steel plate without significant slowdown. When you’re making multiple cuts in thick material, adequate power prevents frustration and reduces the risk of the wheel binding dangerously.
Solving for Safety Features
Kickback brakes stop the wheel quickly if it binds, preventing injuries. This feature, found on premium models like the DEWALT DCG413B, can stop a spinning wheel in under two seconds. For professional metalworking where safety matters, this feature is worth the additional cost.
Soft-start electronics gradually ramp up the wheel speed, reducing the sudden jerk when starting the tool. This feature helps with control and reduces wear on the tool. After using grinders with and without soft start, I’ve found the feature particularly helpful when working in awkward positions where maintaining grip is challenging.
Adjustable guards that can be repositioned tool-free add convenience and safety. Being able to quickly adjust the guard position for different cutting angles encourages keeping the guard in place. I’ve seen too many metalworkers remove guards permanently because adjusting them is difficult. Tool-free guard adjustment helps maintain safe working practices.
Pro Tip: The best safety feature is proper technique. Always maintain a firm grip with two hands when possible, position your body out of the line of potential kickback, and never force the tool through a cut. Let the wheel do the work.
Frequently Asked Questions
What size angle grinder is best for metalworking?
The 4-1/2 inch angle grinder is the most versatile size for general metalwork. It offers good control while providing adequate power for cutting through materials up to 1/4 inch thick. Larger 6 to 9 inch grinders are better for heavy fabrication with thicker steel.
How many amps do I need for metalworking?
For light DIY work with materials under 1/8 inch, 7 to 8 amps is sufficient. Professional metalworking with materials up to 3/8 inch requires 10 to 11 amps. Heavy fabrication cutting 1/2 inch steel or thicker benefits from 13 amps or more.
Corded or cordless angle grinder for metalwork?
Corded grinders offer unlimited runtime and consistent power, making them ideal for shop work. Cordless grinders provide mobility for job sites and tight spaces. Modern 2026 brushless cordless models deliver impressive power but have limited battery life.
What safety features should I look for?
Paddle switches are essential because they stop power if you drop the tool. Kickback brakes stop the wheel quickly if it binds. Adjustable guards, soft-start electronics, and anti-kickback clutches are also valuable safety features to consider.
Which is better: paddle switch or slide switch?
Paddle switches are safer because they require constant pressure to operate. If you lose your grip, the tool stops immediately. Slide switches can lock on, which is convenient but presents a safety risk if the tool is dropped. For metalworking, paddle switches are strongly recommended.
What RPM is best for cutting metal?
Most 4-1/2 inch grinders operate between 10,000 and 11,000 RPM, which is ideal for metal cutting. Larger grinders run at lower RPM but have larger wheel circumference for similar cutting speed. Always match the wheel rating to the grinder speed.
Final Recommendations
After testing these 10 angle grinders extensively on real metalworking projects, my recommendations are clear. For cordless performance, the Milwaukee M18 FUEL 2880-20 stands above the rest with its combination of power, safety features, and battery platform integration. For those preferring corded reliability, the Makita 9557PBX1 offers exceptional value that just keeps working year after year.
Your choice should depend on your specific needs. Consider whether cordless mobility matters for your work, what thickness of metal you’ll be cutting, and whether you already own batteries from a specific platform. The right angle grinder makes metalworking more efficient and enjoyable, while the wrong choice leads to frustration and potentially unsafe situations.