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Cut-Off Tools

Air cut-off tools spin abrasive discs at high speed to slice through metal, plastic, or composite — faster and cooler than most electric alternatives. They're compact, lightweight, and handle awkward angles where a grinder won't fit. The tools listed here take 75 mm (3-inch) discs and run off a workshop compressor; you'll need adequate CFM and a decent regulator to keep speed consistent under load.

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Most of these tools sit around 20 000 RPM free speed and draw between 4 and 6 CFM at 90 PSI. Check your compressor recovery rate — running a cut-off tool continuously on an undersized unit will throttle output and stall the disc mid-cut. Fit a quick-exhaust valve or muffler if noise matters; the exhaust port directs air away from the work, but it's loud in a confined space.

The straight-body designs offer better reach into recesses and behind flanges. Angle-head models (sometimes called rotary cut-off tools) give more leverage for heavier cuts but add bulk. Both types use the same 75 mm discs with a 10 mm bore; keep a stock of thin cutting discs (0.8–1.0 mm) for sheet metal and thicker ones (1.6 mm) for tube and bar. Discs wear fast — budget for consumables, not just the tool.

Trigger throttle lets you feather speed on entry; full-throttle models are simpler and cheaper but harder to control on thin material. Either way, let the disc do the work — forcing it flexes the abrasive and shortens life. Spindle lock is standard; swap discs when they're down to about half diameter or if the cut starts wandering. Oil the air inlet every few hours of use and blow out the motor vanes weekly to keep bearings free.