Die grinder suggestions for projects/repairs ??

[100inchhammer]

Looking at getting a die grinder for projects at our farm. Could have used one this past week instead of using a rat-tail file by hand. Never had a die grinder and my dad never had one either so I'm not sure where to start. Thanks for any suggestions.
Brands ?
Models ?
Corded vs Battery ?
Straight vs Right angle ?

I am an automotive tool & die maker, I use these every day, sometimes an entire shift, all of mine are dotco and Ingersoll brand.

Your main concern right now is how it will be powered (pneumatic, battery, corded). Will you be mainly using this in your shop area where you can use an air line, or do you need it remotely? If it's in your shop I recommend a pneumatic. If it's used remotely then a battery. I've used inexpensive grinders and they work well, all die grinders rely on rpm not hp to do their job. You'll want an A size which is sort of the standard.

Now you'll need burrs (rotary files). You'll need 1/4" shank with a 1/2" dia head for most projects.

If you're grinding on aluminum, have a container of kerosene to dip the burr into frequently, this will prevent the burr from instantly clogging. Steel you need no lubricant.

I have pics of everything mentioned. The cheap grinder has one accessory that I particularly like (an 1/8" collet for intricate work, but you'll need 1/8" shank burrs for that). You can buy an 1/8" collet for the Ingersoll grinder too.

Note one Ingersoll has a front exhaust which i like unless I'm grinding in a cavity (it then blows chips back in your face). The rear exhaust isn't bad but the chips don't get controlled and blown away from you. This will be your choice.

 

[imarobot]

"If you're grinding on aluminum, have a container of kerosene to dip the burr into frequently, this will prevent the burr from instantly clogging. Steel you need no lubricant."
Great tip, thank you. I've had issues with grinding aluminum, now I know how.

 

[snoeproe]

I have one. As a welder, it’s a must have tool. I prefer electric over pneumatic. Straight, not right angle. Makita is what I tend to prefer. I only use carbide grinding burrs on mine. Wear your PPE and don’t shoot the steel slivers upwards into the air. Ear and face protection.

 

[pigdoc]

I used to do a lot of die grinding, and just used the cheapest die grinder I could find. A good used one also works fine for hobbyist work. Shouldn't cost more than $20. Used to buy Chinese bits at the swap meets, 3/$25.
Ya, it's good to find a low traffic area, outdoors, where you don't have to worry about clean-up. Like, 'round behind the outhouse. Usually, they exhaust air towards the bit, so if you can point it away from you, most of the chips will disappear. I'll be doing some tomorrow again, if I can keep the day moving along. Gotta grind some weld spatter off a vintage moped frame (to be painted), clean up the inside of an intake tube, remove some casting and forging flash bits and parting lines here and there on some engine parts...
Back in the day, I ported and chambered 318 cop car heads (swirl-port) to use on the 273 4-bbl. in my '66 Dart wagon. Had the chambers within 0.3cc of each other. Smoothest running V8 I ever owned.
-Paul