TIL my old boss was wrong about using a 4-inch angle grinder for finish cuts

I was cleaning up some old maple trim in a Denver remodel last month and switched from my 4-inch to a 7-inch grinder with a finer wheel. The difference in the cut quality was night and day, with almost no burning or tear-out. What's your go-to tool for tricky finish work on hardwoods?

3 comments

3 Comments

the_alex22d ago

Ever think about how the grinder's weight and balance matter more than just the wheel size? A smaller tool can be harder to control smoothly for that final pass. Sometimes a bigger, steadier machine just gives you a cleaner line.

avery38922d ago

My old shop teacher used to say a heavy grinder just hides a shaky hand. I've found a lighter 4.5 inch tool lets me feel the cut better, especially on curves. That extra weight you like can actually tire your wrist out faster, leading to more mistakes. For a final pass, I want finesse, not just a steady brute. Give me a well-balanced smaller grinder any day.

zarap1422d agoMost Upvoted

That's a solid point from @avery389 about a lighter tool giving more feel. I read a forum post a while back where a cabinet maker swore by using a smaller grinder for the final pass, but only after making the rough cut with a bigger one. He said it was like using two different grits of sandpaper. The heavy 7-inch takes off the bulk without fighting you, then the light 4.5-inch cleans it up with control. For tricky hard maple, that two-step method seems to get the best of both worlds.