DeWalt 60V MAX Brushless Cordless 4.5 in Grinder Kit

First impressions and setup

I put the DeWalt 60V FlexVolt grinder straight to work on a mix of metal and masonry tasks: trimming angle iron for stair stringers, cutting out rusted bolts, and opening up a couple of block cells for conduit. Out of the kit, you get the grinder, a 6.0Ah FlexVolt battery, fast charger, side handle, a Type 27 wheel, and both 4-1/2 in and 6 in guards. Swapping guards is straightforward, and the included wrench and flanges make first setup painless. It’s a tidy kit that actually lets you start working right away, not just stare at an empty bare tool while you wait on accessories.

Balance with the 6.0Ah pack is good. It’s a hefty tool, but the center of gravity sits close enough to the head that you don’t feel like the battery is steering the tool. The side handle threads in where you’d expect and does a lot to keep vibration manageable. The grip shape is comfortable, with enough texture to control the tool when your gloves get dusty or damp.

Power that feels genuinely corded

The headline spec here is corded-equivalent 13-amp performance, and in practice the grinder earns it. It spins to a no-load 9,000 rpm, and once it’s in the cut it doesn’t bog unless you really lean on it. With a quality 4-1/2 in cut-off wheel, it chewed through rebar and 1/4 in steel plate on bracket jobs with the same authority as my mid-tier corded grinder. Where it really separates itself from typical 18/20V grinders is in maintaining speed once the abrasive starts to bite. You can ride a steady feed rate without babying the tool.

Moving up to a 6 in wheel is where this model becomes more than “just another 4-1/2 in cordless.” The extra diameter gives notably more cut depth for masonry and pipe, and at 9,000 rpm the larger wheels still feel lively. I cut slots in CMU and scored brick for an exterior opening using a 6 in masonry wheel; the grinder stayed smooth, and the added reach reduced the number of passes I needed.

Control, braking, and safety

The trigger modulation is predictable, and the electronic brake is excellent. The wheel stops in roughly a second and a half when you let off—fast enough to keep you moving between cuts without waiting or setting a still-spinning grinder on the ground. The kickback brake and E-CLUTCH are more than marketing. I hit a bind cutting a corroded bolt where the kerf pinched; the grinder recognized it immediately, killed the motor, and saved my wrist. That kind of intervention is hard to appreciate until you need it, and it’s a big reason I’m comfortable using this over my older corded units on awkward, overhead cuts.

Runtime realities

Power comes with a cost, and on a high-output 60V grinder the cost is runtime. Expect very different results depending on the task:

• Light cutting and touch-up grinding: One 6.0Ah FlexVolt pack goes a long way. I could tackle a punch list of quick cuts, edge cleanups, and bracket trims on a single charge without thinking about the charger.
• Heavy grinding, beveling, and aggressive wire brushing: You’ll drain packs fast. Wire wheels in particular create constant drag, and continuous grinding at high pressure eats watt-hours quickly.

If you plan on sustained grinding or long wire-wheel sessions, bring more battery. A second pack is mandatory, and stepping up to 9.0Ah or 12.0Ah FlexVolt batteries meaningfully extends working time—at the cost of extra weight. The fast charger keeps downtime reasonable, but no charger is fast enough to make a single battery a full-shift solution for heavy work. If you live on a bench grinder all day or spend hours doing plate bevels, a corded grinder still makes more sense.

Ergonomics and usability

As a daily driver, this grinder is easy to live with:

• Balance and grip are solid with the 6.0Ah pack. You feel the mass, but it’s not fatiguing in typical use.
• Vibration is well-controlled, especially with the side handle installed. On smoother wheels the brushless motor feels refined.
• Guard swaps between 4-1/2 in and 6 in are quick, and visibility around the guard is decent for lining up plunge cuts.
• Wheel changes are standard fare with the spindle lock and wrench. The flanges hold wheels square, and I had no issues with chatter.

Noise is what you’d expect from a 9,000 rpm grinder—this isn’t a quiet tool. Good earmuffs are a must, especially when cutting masonry.

Versatility with 4-1/2 in to 6 in wheels

Having both guards in the kit brings real versatility. I kept the 4-1/2 in guard on for metal fabrication and swapping to the 6 in guard for masonry and deeper cuts. A few practical notes:

• 6 in wheels increase cut depth and efficiency on block, brick, and thicker stock, but they also add inertia. Let the wheel work and avoid forcing the cut.
• For metal, thinner cut-off wheels at 9,000 rpm slice fast and leave a cleaner kerf. Save the grinding discs for shaping and bevels.
• If you plan to cut a lot of masonry, a dust shroud and vacuum are worth adding. The included guard is a safety guard, not a dust extraction system.

Dust, debris, and maintenance

There’s no integrated dust port, so you’ll want a dedicated shroud for serious masonry work. Regardless of the task, blow out the vents and wipe down the tool at the end of the day. Battery contacts and wheel flanges stay cleaner than on some grinders thanks to the guard design, but abrasive dust finds its way into everything. A quick air blast extends the life of both tool and battery.

Battery platform and charging

The included 6.0Ah FlexVolt battery pulls double duty across 20V MAX and 60V MAX tools, which adds value if you’re already on the platform. In this grinder it runs at 60V, unlocking the higher power level that makes the tool feel “corded.” The fast charger gets a depleted 6.0Ah pack back in service in roughly an hour. For a one-battery kit, that’s workable on a punch-list day. For production work, plan on a multi-battery rotation.

Durability and service

The grinder has handled drops, dust, and jobsite transport without loosening up or shedding plastic. Guards lock tight and stay where they’re set. The electronics have been reliable, with no nuisance trips from the E-CLUTCH under normal loads. DeWalt’s 3-year limited warranty, 1-year free service, and 90-day satisfaction policy offer a bit of safety net, which I appreciate on higher-ticket cordless tools that will see hard use.

What I’d improve

No tool is perfect. Here’s what stood out:

• Runtime under continuous heavy load: It’s the tradeoff for real power. Bigger batteries mitigate it but add weight.
• Weight with high-capacity packs: A 9.0Ah or 12.0Ah battery extends work time but makes the tool noticeably back-heavy.
• Dust management: A kit dust shroud would be a welcome addition for users who regularly cut masonry.

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

Who it’s for

• Remodelers, fabricators, and service techs who need corded-like power without running extension cords.
• Masons and concrete crews tackling intermittent cuts and scoring where mobility matters more than unlimited runtime.
• Pros already invested in the FlexVolt ecosystem who want a grinder that can keep up with demanding tasks.

If your day is hours of uninterrupted grinding on heavy plate, a corded grinder (or a generator with corded tools) is still the efficient choice.

Recommendation

I recommend the DeWalt 60V FlexVolt grinder for anyone who needs real, corded-class performance in a cordless package. It cuts and grinds with authority, the electronic brake and kickback protection inspire confidence, and the ability to run both 4-1/2 in and 6 in wheels makes it more versatile than typical compact grinders. The tradeoff is predictable: sustained heavy work will drain batteries quickly. If you plan for that—by carrying a second pack or stepping up in capacity—the tool shines on jobs where cords are inconvenient, unsafe, or simply not an option. For mobile crews and pros already on the FlexVolt platform, it’s an easy yes. For all-day stationary grinding, stick with corded.