DeWalt 20V MAX 4.5 in - 5 in Variable Speed Angle Grinder with FLEXVOLT Advantage (Tool Only)

First impressions and setup

I put the DCG416 to work across a week of metal and masonry tasks—cutting rebar, cleaning welds, deburring stainless, and some quick touch-ups on pavers. Out of the box you get a Type 27 guard, side handle, flange, and a hex key. Battery and charger are on you. The format is familiar if you’ve used DeWalt’s 20V MAX grinders: compact body, tool-free guard adjustment, and a comfortable side handle that threads on securely. The brushless motor and variable-speed control are the headline features here, and they’re the reason I reached for this one over fixed-speed grinders in my kit.

The bare tool is relatively light at just under 4 lb, and it balances well with a 5Ah 20V MAX pack. Swap to a FLEXVOLT DCB606 and you feel the extra heft, but you also feel the bump in output—the “Advantage” part of FLEXVOLT Advantage is real. I’ll get into that more below.

Power and speed control

DeWalt gives you six speed settings with a 9,000 RPM no-load ceiling. On the high end, the DCG416 behaves like a strong compact grinder. Cutting 3/8- to 1/2-inch mild steel stock with thin kerf wheels was brisk and consistent, and blending welds with a 60-grit flap disc didn’t bog unless I leaned in unreasonably. Where variable speed earns its keep is on materials that punish heat and aggression: stainless, aluminum, and brass. Dropping to the mid or lower settings let me keep stainless work cool and controlled, and I could polish with conditioning discs without burning a finish.

Compared to a corded 11–13 amp grinder, this 20V model sits just a notch below on sustained heavy grinding with coarse wheels. With a standard 5Ah pack, you’ll notice the electronic systems protecting the motor if you dig too hard for too long. Pair it with a DCB606 FLEXVOLT and the torque headroom widens; the grinder keeps its speed and recovers more quickly under load. For everyday shop and site tasks, that extra punch is worth the weight penalty.

Safety systems that actually help

The DCG416 layers in three electronic protections: E-CLUTCH, Kickback Brake, and an electronic brake that stops the wheel when you release the trigger. I forced a few binds in scrap material to see how it would react. In a hard pinch during a cut, the Kickback Brake snapped the wheel to a stop fast and the body barely twitched—exactly what I want when a cut closes unexpectedly. I also got the E-CLUTCH to trip on a stall during an aggressive grind; it shut down the motor quickly and reset cleanly once I backed off. In routine use, the decel when you let off the trigger reduces those nerve-wracking spin-down moments that have a way of scuffing workpieces and gloves.

These aren’t bells and whistles for me—they’re the difference between finishing a cut safely and fighting a tool that wants to walk.

Ergonomics and controls

The form factor is compact for a 4.5/5-inch grinder, with enough girth to grip securely in gloves without feeling blocky. Vibration is well-controlled; flap-disc work on plate felt smooth, and the gear case didn’t get uncomfortably hot during longer grinding sessions. The side handle has just enough texture and isolation to cut down on buzz.

The variable-speed selector is easy to reach and positive in its detents. I wish the markings were a bit more descriptive than numbers—translating “Setting 3” to a target RPM range is a trial-by-feel exercise—but once you learn which setting suits a task, you don’t think about it anymore. The trigger and brake behavior are predictable, and wheel swaps are straightforward with the included flange setup.

Battery choices and runtime

Two personalities live inside this grinder. With a 20V MAX 5Ah battery, the DCG416 is light, nimble, and ideal for trim work, quick cuts, and finish grinding. With a DCB606 FLEXVOLT, it becomes a small brute, especially in the top two speeds. That’s the combination I’d reach for when cutting thicker stock, scoring concrete, or running larger-diameter 5-inch wheels where surface speed matters.

Runtime is tied heavily to your wheel and task. Flap disc blending and wire wheel cleanup at mid speeds sip power; heavy grinding and aggressive cutoff on high will drain packs more quickly, as expected. The cooling and electronics are tuned well—you can feel the tool protect itself before things get too toasty, and recovery is quick after swapping packs. For all-day work, plan on rotating multiple batteries, and consider the FLEXVOLT packs if your tasks trend heavy.

Dust control and connectivity

Concrete grinding and tuckpointing are where dust control matters most on a grinder. The DCG416 supports Wireless Tool Control, so you can pair it with a compatible DeWalt dust extractor and have the vac auto-start with the grinder. With a shroud attached for surface prep, the auto on/off made moving between passes much smoother and saved me from chasing a separate switch. The grinder is also Tool Connect chip–ready, which is helpful if you manage a fleet and want asset tracking or geofencing; the chip bay is built in, and adding a DCE042 is quick.

Accessories and compatibility

The included Type 27 guard covers grinding and flap discs. If you’re planning a lot of cutoff work, budget for a Type 1 guard and keep it dedicated to cutting wheels—swapping guards isn’t hard, but I prefer to leave one set up for each role. The DCG416 runs both 4.5-inch and 5-inch wheels, and the extra diameter of a 5-inch disc pays dividends on reach and speed, especially on stainless or when you’re trying to keep heat out of a cut.

The grinder works with all 20V MAX batteries and chargers, and it benefits most from the higher output packs. The warranty is solid for a pro tool: 3-year limited, 1-year free service, and 90-day satisfaction.

Performance notes from the field

• Steel fabrication: With a 60-grit flap disc on speed 5, weld blending was controlled and didn’t wash the surrounding material. Stepping down to speed 3 with a conditioning wheel produced a uniform finish on handrails without burning.
• Stainless cleanup: Running slower speeds with thin cutoff and then flap discs kept discoloration in check. The lower settings make this grinder more versatile than fixed-speed models.
• Masonry: Scoring pavers with a diamond wheel at high speed was clean. With a dust shroud and wireless vac pairing, the workflow was tidy and easy to manage.
• Wire brushing: Speed 2–3 minimized chatter and helped avoid throwing wires, with noticeably less grabby behavior on edges.

Where it fits in the lineup

If you need maximum cordless grinding power for heavy concrete surfacing or continuous stock removal, DeWalt’s 60V models hit harder. The DCG416 positions itself as a versatile, safer 20V grinder that can punch above its class when paired with FLEXVOLT. For many trades—metal fabricators, remodelers, maintenance techs—it’s the sweet spot: one tool that can slow down for delicate finishes and still muscle through everyday cuts.

Limitations and nitpicks

• It’s tool-only. If you don’t already own 20V MAX batteries and a charger, the true cost climbs fast.
• With a DCB606 onboard, the package gets head-heavy. The power is worth it, but you feel it in prolonged one-handed work.
• The speed dial uses numbers rather than RPM ranges. It’s not hard to learn, but a printed guide would shorten the curve.
• You get a Type 27 guard only. Plan to add a Type 1 guard if cutoff work is a staple.

None of these are deal-breakers, but they’re worth planning around.

The bottom line

The DCG416 is a thoughtful evolution of the compact cordless grinder: enough power to replace a cord on most tasks, six-speed control that genuinely broadens what you can do, and safety systems that intervene when things go sideways. Paired with a FLEXVOLT pack, it steps into the “small brute” category; with a 5Ah 20V MAX, it’s a nimble finisher that’s easy to keep in hand all day. Add in wireless dust control and chip-ready tracking, and it’s well-suited for both shops and job sites that value versatility and safety.

Recommendation: I recommend this grinder. If you already live in DeWalt’s 20V MAX ecosystem and want one grinder that can handle delicate stainless work in the morning and chew through angle iron in the afternoon, the DCG416 delivers. Choose your battery to match the day—5Ah for balance, FLEXVOLT for punch—and you’ll cover a lot of ground with one tool. If your work is almost exclusively heavy, continuous grinding, look at a 60V model; otherwise, this variable-speed 20V grinder is the right blend of control, safety, and power.