OP. Wheres your Harrys (Harry Muffs = Ear muffs) or were you using earplugs?
Ear protection is a great idea, it lets you free up a lot of your brain to work safer (less confliction) & a Lot faster.
Even bashing a shaft with a hammer once will make my ears ring for a day.
A few points. (I'm picky as doing this grinding stuff is my job...)
Your grinder guard is a little too far around clockwise, it should be about the 10-4 o'clock position.
You can use the 4 o'clock edge as a lever when you are cutting.
Use a bigger disc if possible, its all about Metres/minute at the cutting face. NEVER use a grinder without a guard or with a oversize disc.
You can grind down a 9 inch disc (in the right grinder!) to 5 inch dia & then put it in a 5 inch grinder. Its safe, its all about centrafugal forces.
To get the Ali bits off, use a hammer, bash it at the join area till it breaks a bit & then bash each end of the shaft inline & the Ali parts will break off.
Ali clogs up the grinder wheel & makes it hard to cut, then you use more force & the wheels gotta break down faster so it will expose new sharp stone to do the cutting.
Use a vice to hold the iron core, or something. When the grindstone jumps as its cutting, it breaks the stone down faster & that uses up good stone for nothing.
Also a moving workpeice is a accident waiting to happen.
It also leaves two hands to hold the grinder, theres also no left hand grip on your grinder. Use the grinder in that position as you did with your left hand 'thumb up' on the grip.
That way, if it grabs, its just gonna pull the grinder away from you & your hands.
Cut thru the wire where you did, a bigger dia wheel helps a lot here....
Once you have got a chunk of wire removed, cut as you did, or use the 1-2 oclock position on the wheel to cut thru the wire thru the side of the loops, you can cut from the outside of the dia, or from the inside towards the outside.
Inside to out works great as the wires are locked into that position & the force of the disc cutting keeps them in place.
Cutting from outside to inside lets loose wires grab & seperate & move towards the open area of the iron cores slots. Copper wire 'grabs' & shifts a lot.
You cut very well, close to the iron core. That leaves less burrs on the wire to catch on the iron core as you pull the wire out later.
Once you have removed all of the end. I find it helps to use a small dia punch (old electric motor shaft) & punch the cut face of the copper wire into the iron core a bit.
That way theres less free copper wire ends to grab onto the edges of the iron core slots. Also it gets the copper wire moving & easyer to pull out from the other side.
I tend to use a long steel rod (computer printer shaft, or screwdriver) to pull the wire out so it gets loose & can be pulled out by hand.
That idea with the triangle shaped lever tool is a really really good idea. Kudo's to the inventor.
You cut very well, close to the iron core. That leaves less burrs on the wire to catch on the iron core as you pull the wire out later.
I tried a ultra thin grinding disc to do this job, to save copper. Bad idea, they don't have the 'side pressure strength' & flex too much.
The disc cracked around the flange & broke off in one peice with a large dia hole in its centre.
Oh well, gotta find out somehow......
The thin tin disc in the ali casting can be popped out with the shaft, I think theres a greasy felt washer & a barrel shaped bronze bearing. They all pop out at once.
The black bakelite part screwed to the ali casting has a bunch of nice silver or silver/copper electrical contacts in it. I grab all of them. Same widda brass bits.
When you change discs, pull the plug out & hold it in your armpit.
In 30 years of using grinders daily, I have only had one very small accident. I cut a small slot in the left hand middle finger knuckle. Taped it up closed & kept it that way for a week. Fixed.
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