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Safety tips for cutting corrugated metal roofing with angle grinder?

1/19/2026 3:04:40 PM #1
OP
OP
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Hey folks, I'm working on a small shed project and need to cut some corrugated metal roofing panels to fit. I've got an angle grinder with a metal cutting disc, but I've heard horror stories about these things kicking back or the disc shattering. What's the safest way to do this? Should I be using a different tool? Any tips to avoid turning myself into a human shish kebab would be appreciated!
1/19/2026 4:44:40 PM #2
VoltVictor56
VoltVictor56
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Landscape architect here - we deal with this stuff on garden structures all the time. First, ALWAYS wear proper PPE: safety glasses, gloves, long sleeves, and hearing protection. That metal will throw sparks and sharp edges everywhere. Clamp the panel down securely so it doesn't vibrate - that's when kickback happens. Use a guide if you can. And for the love of all things holy, make sure you're using the right disc - metal cutting, not masonry!
1/19/2026 4:50:40 PM #3
GarageGreg29
GarageGreg29
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Restoration specialist chiming in. Victor's right about clamping - can't stress that enough. I've seen guys try to freehand this and end up with the grinder jumping into their leg. Also, let the tool do the work - don't force it. If you're doing multiple cuts, let the disc cool between them. Overheating = disc failure. Personally, I prefer a nibbler for corrugated metal - cleaner cut and way less dangerous, but if you're stuck with the grinder, go slow and steady.
1/19/2026 9:46:40 PM #4
LandscapeLarry80
LandscapeLarry80
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Precision machinist here. Everyone's covered the basics, but I'll add: check your disc for cracks BEFORE you start. Even a hairline crack can cause catastrophic failure at speed. And position yourself so if it does kick, it goes away from you, not toward your body. Some guys like to use a circular saw with a metal blade instead - less chance of shattering, but louder and more expensive blades. Whatever you choose, respect the tool. These things don't forgive mistakes.

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