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

1/19/2026 5:04:40 PM #1
OP
OP
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Hey folks, newish DIYer here. I'm running some electrical in my garage and need to cut some 1/2" galvanized steel conduit. I've got a 4.5" angle grinder with a metal cutting 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 more than just safety glasses? Any tips appreciated!
1/19/2026 6:34:40 PM #2
ToolTimeTim43
ToolTimeTim43
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First rule: ALWAYS use a guard on that grinder. I've seen guys take them off for 'better access' and end up with wheels in their legs. For conduit, clamp it down tight - don't try to hold it with your hand. Wear a face shield OVER your safety glasses, leather gloves, and long sleeves. Make sure you're using a proper metal cutting disc, not a grinding wheel. And stand to the side, not in line with the wheel rotation. One more thing - let the tool do the work, don't force it.
1/19/2026 5:50:40 PM #3
HammerHank68
HammerHank68
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Tim's right about the guard - that's non-negotiable. For conduit work, I actually prefer a reciprocating saw with a metal blade. Less chance of kickback, and you can use a conduit bender as a guide. But if you're set on the grinder... make sure the disc is rated for the RPM of your tool. I've seen cheap discs come apart at speed. Also, galvanized gives off nasty fumes when cut hot - do this outside or with serious ventilation unless you want zinc fever.
1/19/2026 10:07:40 PM #4
SanderSid44
SanderSid44
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Not my usual tile mud, but I've cut plenty of metal for custom jobs. What everyone said plus: check that disc for cracks BEFORE you start. Tap it lightly - if it rings clear it's good, if it sounds dead toss it. And for conduit specifically, mark your cut line all the way around so you don't have to reposition mid-cut. Oh, and keep a fire extinguisher nearby - those sparks can ignite dust or fluids real easy.

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