I’ve long had a bit of a Tennis Elbow problem in my right elbow. It started after a weekend at the UK Pinball Party, and it seems that it isn’t going away any time soon. Usually it’s all fine, just if I do a bit of strenuous sawing it aches a bit and I have to be a bit careful of it.
So I was after a cheap method of cutting stock without any effort. I don’t have room for the traditional metal cutting bandsaw, and as my workshop is my back bedroom, a screaming bandsaw might not go down too well with next door. They have a small baby, it screams, but I’m informed that it is “not the same thing at all”.
I unpacked it, and managed to find the angle grinder that I’d bought for cutting up an oil drum to make a furnace (still got to do that…)
I’d seen various unboxing and assembly videos on YouTube, but was surprised to find that the base is cast iron. I’d assumed that it would be nasty plastic. The stand cost me the grand total of £18.25 and my expectations were not high.
Assembly is straightforward, it coped well with the angled handle attachments on the Bosch grinder. I used a square the set the rather primitive vise back jaw square and to set the blade vertical. It’s not blob on, but I’ll be tidying the ends up on the mill so no great worries there.
I’m going to make a few tool holders (using the knurled nuts) so I thought I’d give it a try on the 1 inch square aluminium stock I’ll be using for those. All was not straighforward 😉
It seems that the grinder can’t quite cut all the way through the stock. It left a tiny whisker attached. This is no big deal, but it would be interesting to look at the reasons why.
It seems that the guard on the grinder hits the stock before it cuts all the way through. This is a grinder issue – essentially the grinder is only capable of cutting through one inch – pretty much exactly. Ho hum. It’s no big issue to either flip the stock over and cut through the last bit, or just bend the cut portion off, but it does illustrate the limitations of using an angle grinder rather than one of those dandy Evolution chop saws.
This was the point where I realised that the wear of the cutting discs was significant. I put the disc that I’d used to make two cuts through the inch square aluminium stock on top of a new disc.
I reckon it took about 2mm off the disk on each cut. The discs are not expensive – about 60p each, but combined with the depth restriction it is a significant effect.
You can see each of the four cuts is slightly less deep than before. I was able to snap them apart by just bending them, but I did think about holding the last one in a vise (but then tried a bit harder instead).
So, well worth the few quid, takes up much less space than a gert big chopsaw, but does have restrictions. I’m satisfied with it.