There are a bunch of tools you need to work with metals but an angle grinder is one of the most important tools when you do metalwork. This is because of the multiple uses an angle grinder has that don’t just include metalwork but a bunch of more materials like wood and concrete.
That being said this post will focus only on working with metals and what type of angle grinder is best suited for working with metal.
9-inch vs 4.5-inch angle grinder
A 9-inch and 4.5-inch angle grinder are the most common sizes you can find in a workshop and in stores. Their disks are also more readily available so they are easier to find and you will most likely find them at any hardware store.
There are a bunch of different size angle grinders that include the 6 and 7 inches mainly. A 6 inch grinder is a relatively new machine because you used to only get 4.5, 7, and 9-inch angle grinders. Where the 7 inch is the od one out.
A 4.5-inch grinder is most commonly used when working with smaller items and building smaller projects. The 4.5-inch angle grinder is also commonly used by welders to clean areas for welding or to clean the welds after welding.
The 9-inch angle grinder is your heavy-duty grinder that is used when you need to cut or grind a lot of thicker material. You should always use two hands when working with an angle grinder, especially with a 9-inch grinder.
I did a full and detailed post on how to cut with an angle grinder safely. I use a 9-inch grinder in that example, but the same safety rules apply when using a smaller grinder or even when you are grinding.
When working with metal it is a great idea to have both sized grinders in your tool collection, but if you are strapped for cash or only looking to buy one then the smaller 4.5-inch will be sufficient to start with.
Cordless vs corded angle grinders
A cordless angle grinder uses a battery where a corded one is plugged into the wall. These days cordless angle grinders are powerful enough to do most home, DIY, or light professional work.
Cordless angle grinder
The positives of cordless angle grinders are:
- No need for annoying power cords
- Very portable
The downsides of cordless angle grinders are:
- Have to charge batteries
- Longer than corded
- Be a bit heavier
- Not as powerful as corded
Corded angle grinder
The positives of cordless angle grinders are:
- More powerful as cordless
- No need to wait for a charge
The downsides of cordless angle grinders are:
- Dealing with that annoying power cord
- Always need a power outlet
Final thoughts on cordless and corded
All these positives and negatives weighed against each other I will still prefer a cordless angle grinder for light work around the home or shop. A corded one I would prefer when doing heavy-duty work.
For most people, a cordless one is the best just because you don’t have to deal with the annoying cord. You can also get an extra battery so you always have one that is charged and ready to go when the other one dies.
The best grinder brands
- DeWalt
- Makita
- Milwaukee
- Metabo
- Bosch
- Ryobi
Please note this is all just my opinion and everyone has different experiences with these brands.
Best angle grinders for metalwork in each category
Best cordless 4.5-inch angle grinder
DEWALT FLEXVOLT ADVANTAGE 20V MAX
4.8/5 stars on Amazon (1,000+ reviews)
Like with most DeWalt tools you can buy this 4.5-inch angle grinder has an outstanding build quality and great ergonomic design. The texture grip area helps to improve your grip on the tool and it isn’t too thick so your hand can comfortably fit around it.
It has great safety features to prevent it from starting up by itself when you connect power to it and has a kickback protector to prevent kickback from happening in full.
The 9000rpm and 1550W give it more than enough power for most uses like cutting, grinding and polishing metal. Even with the brushless motor, this will be a great grinder to have around for personal use.
Being only 1 pound or 450 grams without the battery makes this a very lightweight angle grinder. I don’t have to tell you how important weight is when talking about something that you will have to hold firmly in your hands for a few minutes at a time.
It is a bit expensive but for the quality of the tool you get, it is well worth the price.
The major downside is that you don’t get any batteries with the tool, but shouldn’t be of concern if you already have the batteries and charger from other DeWalt tools. If you don’t the battery and charger can cost just as much as this angle grinder on its own.
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Best corded 4.5-inch angle grinder
BOSCH 4-1/2-Inch Angle Grinder
4.7/5 stars on Amazon (4,000+ reviews)
This might not be the literal best 4.5-inch corded angle grinder out there, but this is my personal favorite. I have used these grinders for everything from work to at-home improvements.
These bosch grinders are all-around better than all of the off-brand grinders you can buy and they are relatively cheap compared to the other high-end brands.
They are a bit simplistic lacking any of the features like kickback protection or an e-switch like its high-end competitors. It has a simple clip-in switch and that is that. For what you need they are good enough and will get the job done.
This is a great tool for professionals or beginners on a budget it will last you a long time especially if you use it lightly.
The only real thing that you will need to do is change the brushes on the motor which is simple enough to do if you follow a short tutorial.
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Best 9-inch angle grinder
Unfortunately, you don’t get battery-powered 9-inch angle grinders. This is due to the size of the battery you will need to power such a machine will be too large and heavy causing it to be too uncomfortable to use.
DEWALT Angle Grinder 7-Inch/9-Inch
The Dewalt 9-inch angle grinder has a 5.3 horsepower brushed motor that produces up to 6,000rpm. This is very powerful and is great for heavy-duty work.
It has a keyless adjustable guard, a 5-point handle connection, and a rotatable rear handle. These are great if you have to continuously change your grinding or cutting angle, but you most likely will get the right grip and angle that works for you and rarely adjust those three things.
Like the bosch grinder above the brushes on this grinder are the only real thing you will have to replace after a while of use. In my experience, it is easier to replace 9-inch grinder brushes than 4.5-inch ones so a basic youtube tutorial would be enough.
It is a bit heavy at 16+ pounds, but with that powerful motor, it is understandable. Just remember to always grip it properly and know what you are doing when using it.
You are most likely not going to use this grinder as much as your smaller one but it is still a great addition to your collection you can add.
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Conclusion
It is best to invest in a quality angle grinder because it is a dangerous tool to use and something that doesn’t feel sturdy in your hands can reduce your confidence in your own ability or slip out of your hand due to bad ergonomic design.
These tools mentioned above are my personal top picks and you will find that the other brands do provide a quality products. I will personally use any of the power tools by the listed brands because of their reputation for quality.
