Are you planning on installing a flagstone patio or walkway? If so, you’ll need to know how to cut flagstone to fit your desired shape and size.
While there are various tools you can use for this task, an angle grinder with a diamond blade is a popular choice. However, it’s important to use the right size grinder and take safety precautions to avoid injury.
In this article, we’ll guide you through the steps of cutting flagstone with an angle grinder and share some tips to make the process easier and more efficient.
So put on your safety gear and let’s get started!
How To Cut Flagstone With An Angle Grinder
Step 1: Choose the Right Size Grinder
When it comes to cutting flagstone, the size of your grinder matters. While a small 4-inch angle grinder can be used with a diamond blade, it’s better to opt for a larger 7-inch grinder. This will make the job faster and easier, as the larger blade can cut through the stone more efficiently.
Step 2: Prepare Your Safety Gear
Before you start cutting, make sure you have all the necessary safety gear. This includes goggles or a face shield, gloves, earplugs, and a dust mask. The latter is especially important as cutting flagstone creates a lot of dust.
Step 3: Secure the Stone
Place the flagstone on a firm surface with the part you’ll be cutting an inch or two off the ground. To make the process easier on your back, use a table or workbench where you can place the stones for cutting.
Step 4: Score the Line
Use the saw to score the line you’ve marked without cutting all the way through the stone. This will help you see where to cut once the piece gets covered in dirt and ensure that the stone will break in the right place.
Step 5: Cut Along the Line
Work your way back and forth along the line until you’ve cut all the way through. Take your time and be patient, as rushing can lead to mistakes or accidents.
Step 6: Cut Curves or Shapes
If you need to cut curves or shapes, a small angle grinder works really well. Just be sure to take extra care and go slowly to avoid mistakes.
Choosing The Right Angle Grinder And Diamond Blade
When it comes to choosing the right angle grinder and diamond blade for cutting flagstone, there are a few factors to consider. First, make sure you select a larger 7-inch grinder for more efficient cutting. Additionally, it’s important to choose the right diamond blade for the job.
Blade thickness is measured at the periphery and includes the plated diamond thickness. For small diameter blades (1-1/2” to 4”), a 1/16” blade is faster for straight cuts, but a thicker blade (3/32”) is advisable for radius/curved cuts with more side pressure. Larger blade diameters (5” to 16”) need to be thicker to retain their rigidity and avoid warping.
When it comes to diamond grit, there are many options available, but three in particular (35/40, 45/50, 60/70) are used in the majority of electroplated diamond blades and tools. For cutting flagstone, it’s recommended to use a medium grit blade such as 45/50, which offers a good compromise between speed of cut and finish.
In addition to selecting the right diamond blade, make sure you have all the necessary safety gear before starting the cutting process. This includes goggles or a face shield, gloves, earplugs, and a dust mask. Take your time and be patient when cutting flagstone to avoid mistakes or accidents.
Preparing Your Work Area And Safety Gear
Before you start cutting flagstone with an angle grinder, it’s important to prepare your work area and safety gear. This will ensure that you can work safely and efficiently, without risking injury or damage to your equipment.
First and foremost, make sure you have a clean and well-lit work area. Remove any clutter or obstacles that could get in the way of your work, and ensure that the area is well-ventilated to reduce the amount of dust and debris in the air.
Next, gather all the necessary safety gear. This includes goggles or a face shield to protect your eyes from flying debris, gloves to protect your hands from cuts and abrasions, earplugs to protect your hearing from the loud noise of the grinder, and a dust mask to protect your lungs from the dust created by cutting flagstone.
Once you have all your safety gear, put it on before you start working. Make sure that everything fits correctly and is comfortable to wear, as this will help you stay focused on your work and avoid distractions.
Finally, make sure that the flagstone is securely placed on a firm surface before you start cutting. If possible, use a table or workbench to elevate the stone and make it easier to work on. This will also help reduce strain on your back and neck, which can be a common problem when working with heavy materials like flagstone.
By taking these steps to prepare your work area and safety gear, you’ll be able to work safely and efficiently when cutting flagstone with an angle grinder. Remember to always prioritize safety when working with power tools or heavy materials, as accidents can happen quickly and without warning.
Marking And Measuring Your Flagstone
Before you start cutting your flagstone, you need to mark and measure it carefully to ensure that you get the right size and shape. Here’s how to do it:
Step 1: Measure the Space
Use a tape measure to measure the space where your flagstone will go. This will help you determine the size and shape of the stone you need to cut.
Step 2: Mark the Stone
Use a pencil or chalk to mark the stone across the top and bottom face with cutting lines. Make sure that your lines are straight and even, as this will help you make accurate cuts.
Step 3: Secure the Stone
After marking the flagstone, position it on a flat surface off the ground. You can use a non-slip mat to hold it in place during cutting, or use a clamp to secure the slab to your work surface. Alternatively, you can position the slab on top of a step so that the part with the scored line is at the end and is hanging over.
Step 4: Cut Along the Marked Line
Using the grinder, cut along the marked line on the top side of your flagstone. Start with a shallow surface cut, adjusting the depth of the saw until you reach about 1/2 to 1 inch. Flip the slab over and repeat the same cutting process until you have a clean break. Remember not to force the blade, as letting the machine do all the work will prevent any damage to your work surface.
Step 5: Tap Until It Breaks
Place the flagstone on your work surface and use a rubber mallet to tap the waste portion to break along the cutting line. Congratulations! Your flagstone is now cut to size and ready to use.
By following these steps, you can mark and measure your flagstone accurately and cut it with an angle grinder like a pro. Remember to always prioritize safety by wearing proper gear and taking your time during each step of the process.
Making The Cuts With Your Angle Grinder
To make the cuts with your angle grinder, you’ll need to follow these steps:
Step 1: Mount the Blade
Mount a diamond blade on your angle grinder. Make sure it’s the right size for your grinder and the job you’re doing.
Step 2: Secure the Flagstone
Prop up the long side of the flagstone and hold it securely. You can use clamps or a vice to keep it in place if needed.
Step 3: Score the Line
Use a pencil or chalk to mark the line where you want to cut. Then, use the saw to score the line without cutting all the way through.
Step 4: Cut Along the Line
Drop the blade through the stone, allowing the weight of the tool to do most of the work. Work your way back and forth along the line until you’ve cut all the way through.
Step 5: Avoid Binding
Allow the short end of the stone to drop freely as you cut to avoid binding the blade. This will help you make clean cuts and avoid accidents.
Step 6: Clean Up
Once you’ve made your cuts, use a wire brush or a damp cloth to clean up any dust or debris. This will help you see your cuts more clearly and make any necessary adjustments.
By following these steps, you can make precise cuts with your angle grinder and create beautiful flagstone pieces for your outdoor projects. Just be sure to take your time, wear protective gear, and follow all safety guidelines when using power tools.
Smoothing And Finishing Your Flagstone Pieces
Once you’ve cut your flagstone pieces to the desired size and shape, it’s time to smooth and finish the edges. This will give your patio or walkway a polished and professional look.
Step 1: Sand the Edges
Using a hand-held stone sander or sandpaper, gently sand the edges of the flagstone piece to smooth out any rough spots or sharp edges. Work slowly and carefully to avoid damaging the stone.
Step 2: Round the Corners
To create a more natural look, round the corners of the flagstone piece using a stone file or sandpaper. This will also help prevent any injuries from sharp corners.
Step 3: Wash and Seal
Once you’ve finished smoothing and rounding the edges, wash the flagstone pieces with soap and water to remove any dust or debris. Let them dry completely before applying a sealant to protect them from weather damage and staining.
By following these steps, you can cut and finish your flagstone pieces with an angle grinder to create a beautiful and functional patio or walkway. Just remember to take your time, wear proper safety gear, and work carefully to avoid mistakes or accidents.
Cleaning Up And Properly Storing Your Tools.
After you’ve finished cutting your flagstone, it’s important to clean up your workspace and properly store your tools. This will help to keep your tools in good condition and prevent accidents in the future.
First, clear the area of any debris or dust. Use a broom or vacuum to clean up any leftover dust or stone fragments. This will help to prevent any accidents from slipping on loose debris.
Next, unplug or remove the battery from your grinder when changing the disc or wheel. This will prevent any accidental starts or injuries.
Make sure the handles of your grinder are firmly attached and keep a firm grip on the tool while using it. If your grinder has a guard, use it to protect yourself from sparks and debris.
When buying a new disc or blade, run it in the grinder for at least 30 seconds to make sure it’s not defective. Do this in a safe space away from anything flammable.
Always make sure that the blade is spinning away from you and be aware of sparks that could catch on anything combustible in your workspace.
When working with an angle grinder, wear goggles, tough gloves, protective boots, and a dust mask. Cutting flagstone creates a lot of dust, so it’s essential to protect yourself from inhaling any harmful particles.
After you’ve finished using your tools, clean them thoroughly and store them in a safe place. This will help to prolong their lifespan and prevent any accidents from occurring.
In conclusion, cutting flagstone with an angle grinder can be a challenging task but with the right tools and safety precautions, it can be done successfully. Remember to choose the right size grinder, prepare your safety gear, secure the stone, score the line, cut along the line, and clean up and properly store your tools.