Features
- Variable speed control with six settings
- Brushless motor
- No-load speed: 9,000 RPM
- Compatible with 4.5 in and 5 in discs
- E-CLUTCH: electronic clutch that shuts down the motor rapidly when a pinch or stall is detected
- Kickback Brake: electronic brake that engages on pinch, stall, or bind-up to stop the wheel and reduce movement
- Electronic brake engages when the trigger is released to stop the wheel quickly
- Delivers increased power when paired with a FLEXVOLT DCB606 battery versus a DCB205 20V MAX battery
- Tool Connect chip ready (accepts Tool Connect chip DCE042; sold separately)
- Wireless on/off capability when paired with a compatible dust extractor via Wireless Tool Control system
- Includes Type 27 guard, side handle, hex key, and flange
- Compatible with all 20V MAX batteries and chargers (battery/charger sold separately)
Specifications
Battery Type | Lithium Ion |
Battery Voltage (V) | 20 |
Disc Diameter (In) | 4.5 / 5 |
Has Secondary Handle | Yes |
Is Battery Included | No |
Brushless | Yes |
No Load Speed (Rpm) | 9000 |
Number Of Speed Settings | 6 |
Power Source | Cordless |
Product Height (In) | 5.7 |
Product Length (In) | 13 |
Product Width (In) | 6.495 |
Product Weight (Lbs) | 3.92 |
Product Weight (Oz) | 62.72 |
Voltage (V) | 20 |
Included Accessories | Type 27 guard; side handle; hex key; flange |
Warranty | 3 Year Limited Warranty; 1 Year Free Service; 90 Days Satisfaction Guaranteed |
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Cordless brushless angle grinder for 4.5–5 in discs with variable-speed control. Six speed settings and a 9,000 RPM no-load speed. When paired with a FLEXVOLT DCB606 battery it produces more power than when used with a standard 20V MAX battery. Includes electronic safety systems (E-CLUTCH and Kickback Brake). Battery and charger sold separately.
DeWalt 20V MAX 4.5 in - 5 in Variable Speed Angle Grinder with FLEXVOLT Advantage (Tool Only) Review
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.
Project Ideas
Business
Mobile Metal Prep and Repair
Offer on-site cutting, grinding, and surface prep for gates, railings, trailers, and small weld repairs. The cordless grinder reaches tight locations and pairs well with a portable welder. Services include rust removal, beveling for weld prep, grinding welds flush, and repaint-ready finishing. Target property managers and homeowners; charge per hour or per job with add-ons for coatings.
Concrete Grinding and Floor Prep
Provide small-area concrete grinding: trip-hazard removal, crack edge cleaning, coating/epoxy prep, and high-spot leveling. Use diamond cups at controlled speeds and connect a compatible dust extractor via Wireless Tool Control for cleaner, compliant work. Market to garages, basements, patios, and storefronts. Price per square foot with tiered rates for adhesive removal vs. profiling.
Lawn and Tool Edge Sharpening (Mobile Pop-Up)
Sharpen mower blades, axes, hoes, and chisels using flap and sanding discs with variable speed to control heat and preserve temper. Offer neighborhood pop-up days or pickup/drop-off. Include rust removal and edge refinishing upsells. Fast electronic braking improves throughput and safety when swapping pieces. Bundle seasonal maintenance packages.
Rust Removal and Paint Prep for Fences/Handrails
Specialize in surface restoration: remove rust and old paint with wire wheels and coarse flap discs, then smooth and key surfaces for primer. The grinder’s safety systems reduce kickback on uneven bars and scrollwork. Offer package pricing that includes prep, priming, and optional topcoat. Target HOAs, landlords, and historic properties.
Artisan Decor Microbrand
Design and sell small-batch metal-and-concrete goods: planters, wall hooks, shelf brackets, and small sculptures. Use the grinder for clean cuts, chamfers, brushed finishes, and exposed-aggregate effects. Highlight cordless efficiency and consistent finishes in your branding. Sell via Etsy, local markets, and wholesale to boutiques; create limited runs and custom commissions for higher margins.
Creative
Sculpted Concrete Planters with Exposed Aggregate
Cast simple concrete blanks, then shape and chamfer them using a 5 in diamond blade and finishing with flap discs at lower speeds to minimize chipping. Use a wire cup brush to expose aggregate for a terrazzo-like finish. The cordless grinder lets you work outdoors where dust is less of an issue, and the E-CLUTCH/Kickback Brake adds safety when the wheel pinches. Create geometric, faceted, or organic forms and seal them; sell as pairs or themed sets.
Reclaimed Metal Garden Art Sculptures
Cut silhouettes and abstract shapes from salvaged steel, then radius edges and blend welds with flap discs. Use variable speed to control heat tint and produce brushed or mirror accents. Add texture with a grinding stone, then clear-coat or apply a controlled patina. The cordless setup makes it easy to compose pieces in the yard for scale. Produce seasonal motifs, house numbers, or wind-spinners.
Live-Edge Wood + Steel Side Table
Fabricate minimalist steel legs from flat bar or angle stock, cutting and beveling with cutoff wheels. Remove mill scale and blend welds with 60–120 grit flap discs for a clean, brushed finish. Carefully use sanding/polishing pads on the live-edge underside for a tight fit to the steel. The grinder’s six speeds help avoid blueing and keep corners crisp. Finish with a matte clear and wood oil.
Custom Tile Mirror with Metal Frame
Build a thin steel frame for a mirror, then use the grinder to round corners, bevel inside edges, and smooth welds for a seamless look. Trim and ease tile edges with a diamond wheel and finish at lower speed to reduce chipping. Set mosaic or terrazzo tiles around the mirror for a boutique look. The quick electronic brake makes detail work around the frame safer and faster.
Wall-Mounted Bike Rack with Brushed Steel Finish
Cut and notch steel tube or flat bar for a compact bike hanger, rounding contact points and chamfering edges with the grinder. Create a uniform brushed finish using medium then fine flap discs at progressively lower speeds. Add a wood backer for aesthetics. Powder coat or clear-coat the steel. This project showcases precise grinding, clean lines, and premium finishes.