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Need safety tips for cutting galvanized steel conduit with my angle grinder

1/14/2026 2:04:40 PM #1
OP
OP
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Hey guys, newbie here. I'm installing some outdoor lighting and need to cut a few pieces of 1/2" galvanized steel conduit. I've got a 4.5" angle grinder with a cutoff wheel, but I've heard horror stories about these things kicking back or the wheel exploding. What's the safest way to do this without ending up in the ER? Should I be wearing something specific besides safety glasses? Thanks in advance!
1/14/2026 3:19:40 PM #2
SafetySteve72
SafetySteve72
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OP, listen up - this is serious business. First, ALWAYS use a guard on that grinder, no exceptions. Make sure your cutoff wheel is rated for metal (not masonry!) and check for cracks before use. Wear a face shield OVER your safety glasses, leather gloves, and long sleeves. Clamp the conduit securely - never hold it with your hand. Cut slowly, don't force it. And for god's sake, keep bystanders away. One wrong move and that wheel can frag into a hundred pieces.
1/14/2026 4:08:40 PM #3
DemoDave52
DemoDave52
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Steve's not wrong, but man he makes it sound like you're defusing a bomb lol. I cut this stuff all the time for landscape lighting. Pro tip: mark your cut line with a sharpie, use a vise if you have one. Let the tool do the work - if you're pushing hard, something's wrong. Also, galvanized gives off nasty fumes when hot, so do this outside or with good ventilation. Oh, and ear protection! Those grinders are loud as hell.
1/14/2026 6:10:40 PM #4
LumberLuke67
LumberLuke67
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HVAC guy here - we cut galvanized all day for ductwork. Couple things others missed: 1) Position yourself so if it kicks, it goes away from you, not toward your body. 2) Let the wheel stop completely before setting it down. 3) If the conduit starts vibrating like crazy, stop immediately - means your wheel is binding. And yeah, what Dave said about fumes... zinc fever is no joke. You'll feel like you have the flu for days.
1/14/2026 8:32:40 PM #5
LandscapeLarry80
LandscapeLarry80
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Precision machinist perspective: Everyone's covered the basics well. I'll add - inspect that cutoff wheel's max RPM rating and make sure it exceeds your grinder's speed. Mismatch = disaster. Consider a metal cutting bandsaw if you're doing more than a couple cuts - cleaner, safer, and no sparks flying everywhere. But if you're sticking with the grinder, Steve's face shield advice is golden. Saw a guy once who skipped it... let's just say he's eating through a straw now.

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