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Cutting & Grinding

larger angle grinderDepending upon the shape and size of the metal he is cutting for a sculpture in progress, Kevin uses a variety of tools in his studio, including a plasma cutter, Beverly shear, jump shear, plate shear, chop saw, nibbler and air cut-off tool.

For grinding, he may use a larger and a medium sized angle grinder, air angle grinder, die grinder and pencil grinder.

Enjoy these metal cutting and grinding how-to videos ....

How to Cut Pipe Angles Accurately
How to Cut Pipe Angles Accurately
Oct 18, 2017
Kevin has a piece of pipe with a 45 degree angle cut on one end. What if you want to cut exactly the... read more

How to Use CAD to Create Parts for a CNC Table
How to Use CAD to Create Parts for a CNC Table
Oct 11, 2017
Kevin is sitting at his desk with a computer in front of him, ready to show you how to make a part i... read more

How to Use Step Drills
How to Use Step Drills
Sep 27, 2017
One thing Kevin loves about his job is that he's always learning something. He's always finding out ... read more

How to Drill With Annular Cutters (& Why You'd Want To)
How to Drill With Annular Cutters (& Why You'd Want To)
Aug 30, 2017
Kevin shows an annular cutter. It's hollow, has six cutting tips on its end, and has a bit of a cutt... read more

How to Run a CNC Metal Cutting Table - An Overview
How to Run a CNC Metal Cutting Table - An Overview
Aug 23, 2017
Kevin wants to share what he had to learn to get his Dynatorch Super B CNC table running. It wasn't ... read more

How to Use the Evolution EVOMAG 75 Magnetic Drill
How to Use the Evolution EVOMAG 75 Magnetic Drill
Aug 16, 2017
A magnetic drill has a big electromagnet in its base. A magnetic drill allows you to drill holes in ... read more

An Introduction to the Dynatorch Super B CNC Plasma Table
An Introduction to the Dynatorch Super B CNC Plasma Table
Jul 18, 2017
Kevin just bought a new Dynatorch Super B 4x4 Plasma CNC table.

A plasma CNC table is a plasma c... read more

How to Remove Rust the Easy Way
How to Remove Rust the Easy Way
Mar 15, 2017
Kevin is picking old railroad spikes out of a 55-gallon-drum for a railroad spike sculpture. Rather ... read more

How to Use Specialty Nozzles to Improve Plasma Cutting
How to Use Specialty Nozzles to Improve Plasma Cutting
Jan 04, 2017
Kevin is looking at the old cap, or nozzle, from his AHP AlphaCUT 60 plasma cutter. It screws on the... read more

How to Custom Fit Metal
How to Custom Fit Metal
Nov 23, 2016
Kevin is working on a big aluminum sound sculpture stand that will hold three bells. He is fitting t... read more

How to Create Sharp Edges When Fabricating Metal
How to Create Sharp Edges When Fabricating Metal
Nov 16, 2016
For a large bell sculpture Kevin is welding, he is experimenting with 5051 aluminum, fixing areas c... read more

How to Cut Thin Metal Precisely
How to Cut Thin Metal Precisely
Oct 12, 2016
Kevin gets asked often how to get a clean cut on a piece of thin metal.

There are three tools th... read more

How to Cut Metal With A Circular Saw
How to Cut Metal With A Circular Saw
Sep 14, 2016
The EVOSaw 230 circular saw is a big, heavy saw with a lot of truly helpful features.

Right away... read more

Win Your Own FREE Evolution Evo Chopsaw!
Win Your Own FREE Evolution Evo Chopsaw!
Aug 02, 2016
The folks over at Evolution sent Kevin an extra Evo Chopsaw to give away.

To win this brand new,... read more

How to Use a Chopsaw Using the Evolution Evo Chopsaw
How to Use a Chopsaw Using the Evolution Evo Chopsaw
Jul 20, 2016
Kevin first gives a tour of Evolution's Evo Chopsaw, a 14" metal cutting chopsaw with a toothed blad... read more

How to Cut Pipe at an Angle Accurately
How to Cut Pipe at an Angle Accurately
Jun 01, 2016
A viewer, Dave, wrote in and asked how to cut angles on pipe so you can weld them together.

Ther... read more

How to Clean Up Welds in Tight Places
How to Clean Up Welds in Tight Places
May 04, 2016
A viewer, Mike, is MIG welding a gate and wants to know how to clean up his welds in areas that are ... read more

Plasma Cutting:
Plasma Cutting: "What Could Possibly Go Wrong?!"
Feb 24, 2016
Kevin is working on a new fountain and needs to cut some metal to skin the sides of the water featur... read more

How to Get a More Accurate Cut on Metal - Kevin Caron
How to Get a More Accurate Cut on Metal - Kevin Caron
Feb 17, 2016
Kevin is about to true up a piece of steel for his latest sound sculpture. A viewer recently asked h... read more

How to Organize Your Shop Cutting Area for Ease & Efficiency
How to Organize Your Shop Cutting Area for Ease & Efficiency
Jan 05, 2016
Kevin is getting ready to start a sound sculpture and needs to cut some stock, which makes it a grea... read more

How to get a Better Cut With Your Plasma Cutter
How to get a Better Cut With Your Plasma Cutter
Dec 30, 2015
Kevin was about to cut some metall with his plasma cutter, so he got out some "training wheels," or ... read more

How to Cut More Accurately With Your Plasma Cutter
How to Cut More Accurately With Your Plasma Cutter
Dec 23, 2015
Kevin has been playing with the AHP AlphaCUT 60 plasma cutter and is just about to try out some new ... read more

Introducing the New AHP AlphaCut 60 Plasma Cutter
Introducing the New AHP AlphaCut 60 Plasma Cutter
Nov 25, 2015
AHP Tools - known for its powerful, affordable TIG welder - has just released its plasma cutter, a 6... read more

How to Best Set Your Plasma Cutter for Cutting Metal
How to Best Set Your Plasma Cutter for Cutting Metal
Nov 11, 2015
Kevin is often asked how to set a plasma cutter the best way - how much amperage do you want for wha... read more

How to Drill Large Holes With a Mill - and Why It's Better Than Using a Drill Press
How to Drill Large Holes With a Mill - and Why It's Better Than Using a Drill Press
Sep 16, 2015
Kevin is making a commissioned fountain and needs to cut a 3" hole in the center of the water featur... read more

Cutting Metal:
Cutting Metal: "What Could Possibly Go Wrong?!"
Aug 26, 2015
What could possibly go wrong with cutting tools? First Kevin talks about his DeWalt 872 chopsaw. It ... read more

What Are Collets and How Do You Use Them?
What Are Collets and How Do You Use Them?
Aug 12, 2015
Collets are a sleeve that uses pressure and friction to hold something in place. They're used in TIG... read more

How to Use Everlast's PowerPlasma 80S Plasma Cutter
How to Use Everlast's PowerPlasma 80S Plasma Cutter
Aug 05, 2015
Kevin is playing with Everlast's PowerPlasma 80S big plasma cutter with 80 amps worth of cutting pow... read more

How to Use a Metal Lathe
How to Use a Metal Lathe
May 27, 2015
A viewer had asked Kevin for basic information about his lathe so he knows where to start.

Kevin ... read more

How to Make Parts Uniform Using A Mill
How to Make Parts Uniform Using A Mill
Apr 22, 2015
Caron is adjusting his Bridgeport mill (milling machine) to help him make some braces for a fountain... read more

How to Cut a Gas Cylinder With a Horizontal Bandsaw
How to Cut a Gas Cylinder With a Horizontal Bandsaw
Mar 25, 2015
Kevin is ready to give his Ellis 1800 series horizontal bandsaw its first real job. He's cut some sm... read more

How to Pick the Right Grinding Stone for the Job
How to Pick the Right Grinding Stone for the Job
Mar 11, 2015
Kevin is reading a catalog from Random Products, learning more about the grinding wheels, cut-off wh... read more

How to Use a Horizontal Bandsaw - and Why You Would Want to Use It
How to Use a Horizontal Bandsaw - and Why You Would Want to Use It
Feb 25, 2015
Kevin has been thinking about getting a horizontal bandsaw for a while because of some of the bigger... read more

How to Get Stronger Welds With Thick Metal
How to Get Stronger Welds With Thick Metal
Aug 13, 2014
Kevin is clamping a piece of 1/2" steel plate to his work table. He was just about to chamfer the ed... read more

Introducing Longevity's ForceCut 62i Plasma Cutter
Introducing Longevity's ForceCut 62i Plasma Cutter
Jul 23, 2014
Until now, Kevin has been cutting with Longevity's ForceCut 42i, which is a 40 amp plasma cutter. Th... read more

Grinding Metal: "What Could Possibly Go Wrong?!"
Grinding Metal: "What Could Possibly Go Wrong?!"
Jul 02, 2014
When working with metal, there are plenty of things that can go wrong while grinding that can make a... read more

Advantages and Challenges of a Cold Cut Chopsaw
Advantages and Challenges of a Cold Cut Chopsaw
Jan 22, 2014
Kevin got a lot of questions from his last how-to video about his chopsaw - a lot of guys hadn't see... read more

How to Seamlessly Join Two Pieces of Pipe
How to Seamlessly Join Two Pieces of Pipe
Jan 15, 2014
Sometimes you are working on a project - making a fence, a cage, whatever - and your pipe or rod is ... read more

How to Cut Perfect Holes in Metal
How to Cut Perfect Holes in Metal
Dec 18, 2013
In response to a question about how he cut the holes in the steel wings of a private art commission ... read more

How to Cut Pipe With a Plasma Cutter
How to Cut Pipe With a Plasma Cutter
Apr 10, 2013
Kevin needs to cut a steel pipe lengthwise at a taper (why make it easy?!), so he gets out the exten... read more

How to Cut Metal Using a Circle-Cutting Tool
How to Cut Metal Using a Circle-Cutting Tool
Apr 03, 2013
Kevin tries out a new tool, a circle cutter for his oxygen-acetylene unit (oxy-acetylene can cut rea... read more


How to Get Better Results Using Specialty Grinding Pads
Mar 06, 2013
During a trip to his local welding store, Kevin picks up some specialty grinding pads, also known as... read more

Introducing the New Longevity ForceCut 42i Plasma Cutter
Introducing the New Longevity ForceCut 42i Plasma Cutter
Dec 19, 2012
Kevin breaks out Longevity's new ForceCut 42i dual voltage plasma cutter. He admires the clean look ... read more

How to Easily Sharpen TIG Welding Tungstens
How to Easily Sharpen TIG Welding Tungstens
Nov 07, 2012
Ever ingenious, Kevin shares a trick he uses to easily sharpen the tungstens for his TIG welder. Thi... read more

How to Create a Sculpture, Part 12: Grinding and Finish Work
How to Create a Sculpture, Part 12: Grinding and Finish Work
Aug 15, 2012
With just a few panels left to weld on to the structure, Kevin is increasingly turning to finish wor... read more

How to Cut Metal Evenly and Easily
How to Cut Metal Evenly and Easily
Aug 01, 2012
To create a new sculpture, Kevin shows how he slices 5-inch square tubing evenly and easily with his... read more

How to Shine Metal
How to Shine Metal
Jul 11, 2012
Kevin shows how to get a mirror shine on metal using Scotch-Brite pads. In this how-to video, he use... read more

Why and How to Use Flap Discs for Grinding
Why and How to Use Flap Discs for Grinding
Jul 05, 2012
Kevin shows how he finishes his sculptures with sanding pads called flap discs, or soft pads. He exp... read more

How to Cut Metal Without Traditional Metal Cutting Tools
How to Cut Metal Without Traditional Metal Cutting Tools
Jun 13, 2012
In response to a viewer from Kuwait, Kevin gives several "work arounds" for cutting metal as thick a... read more

How to Create a Sculpture, Part 4
How to Create a Sculpture, Part 4
Mar 14, 2012
Kevin continues his series on how to create a sculpture - at least how he creates a sculpture (altho... read more

How to Create a Sculpture, Part 3
How to Create a Sculpture, Part 3
Mar 07, 2012
In the third part of a series on how he is creating a sculpture, Kevin explains how to fabricate rep... read more

How to Use a Pencil Grinder for Grinding Metal
How to Use a Pencil Grinder for Grinding Metal
Jan 26, 2012
Kevin shows one of the tools he uses for grinding metal in tight spots, a pencil grinder. He shows b... read more

How to Set Up a Longevity Plasma Cutter
How to Set Up a Longevity Plasma Cutter
Dec 28, 2011
Kevin shows the parts of the Longevity ForceCut 60i Plasma Cutter and how to set it up. Then he cuts... read more

How to Cut Aluminum the Easy Way
How to Cut Aluminum the Easy Way
Dec 07, 2011
Kevin is starting a new public art sculpture, which will be made of aluminum. To cut the sheets of m... read more

Plasma Cutter Tip Tricks
Plasma Cutter Tip Tricks
Apr 19, 2011
Kevin often uses a plasma cutter. Using a fresh cutting tip helps him make clean, precise cuts. Kevi... read more

Plasma Cutting Technique
Plasma Cutting Technique
Apr 13, 2011
Cutting metal is easy with a plasma cutter. Kevin shows his plasma cutter and how it works. ... read more

Metal Cutting Tools: Using a Beverly Shear
Metal Cutting Tools: Using a Beverly Shear
Dec 30, 2010
To cut sheet metal in a clean curve, sculptor Kevin Caron uses a throatless Beverly shear, a classic... read more

Cutting a Circle for a Metal Sculpture With Oxygen Acetylene
Cutting a Circle for a Metal Sculpture With Oxygen Acetylene
Dec 03, 2010
To cut a 1" thick steel base for a sculpture, Kevin adapts a plasma cutter cutting tool for his oxyg... read more

Metal Cutting: How to Use Oxygen Acetylene
Metal Cutting: How to Use Oxygen Acetylene
Sep 08, 2010
Kevin usually uses his plasma cutter for cutting metal, but sometimes the oxygen-acetylene torch is ... read more

Metal Cutting Tools: Plasma vs. Oxygen Acetylene
Metal Cutting Tools: Plasma vs. Oxygen Acetylene
Aug 31, 2010
Kevin compares two more metal cutting tools: the plasma cutting torch and the oxygen acetylene cutti... read more

Cutting Metal: How to Select the Right Tool for the Job
Cutting Metal: How to Select the Right Tool for the Job
Aug 25, 2010
Kevin shares his thought process on choosing cutting tools - air tools and pneumatic tools includin... read more

Grinding Metal: How to Select the Right Tool for the Job
Grinding Metal: How to Select the Right Tool for the Job
Aug 11, 2010
Kevin has an arsenal of tools for grinding. He shares his favorites, including power and pneumatic t... read more

Cutting Metal: How to Make Components Uniform in Size and Shape
Cutting Metal: How to Make Components Uniform in Size and Shape
Jun 24, 2010
There are times Kevin wants components to look the same within a composition. That's the case on the... read more

Working With Metal: The Right Way to Grind
Working With Metal: The Right Way to Grind
May 26, 2010
After doing a lot of grinding, Kevin realized there's a way to grind that keeps his edges sharp. He... read more

Metal Cutter: Plasma vs. the Nibbler
Metal Cutter: Plasma vs. the Nibbler
Apr 23, 2010
Kevin explains the differences between, advantages and disadvantages of a plasma cutter compared wit... read more

Metal Cutting Tools: How to Use Foot and Bench Shears
Metal Cutting Tools: How to Use Foot and Bench Shears
Dec 09, 2009
There are all sorts of cutting tools, and you want the right tool for the job. Kevin shows how he us... read more

Welding and Grinding Metal
Welding and Grinding Metal
Sep 23, 2009
With the skin now on the stand for BobbyPin, Kevin's new bell, it's time for the tedious part: touch... read more

Cutting Stainless Steel Donut Feet for a Metal Sculpture
Cutting Stainless Steel Donut Feet for a Metal Sculpture
May 04, 2009
To give a stainless steel sculpture a more stable yet still elegant base, Kevin cuts small "donuts,"... read more

Metal Artist Kevin Caron Shows How to Make Steel Donuts
Metal Artist Kevin Caron Shows How to Make Steel Donuts
Apr 24, 2009
Kevin uses the plasma cutter with circle cutter attachment, grinder and air hammer (air shaper) to m... read more

Grinding Steel Hands for a Public Art Commission
Grinding Steel Hands for a Public Art Commission
Mar 18, 2009
Kevin grinds away at the project Hands On for the city of Avondale, Arizona. In preparing 200 indivi... read more

Inside a Cool Tool, the Plasma Cutter
Inside a Cool Tool, the Plasma Cutter
Dec 08, 2008
While performing a "cablectomy" on his plasma cutter, Kevin shows the inside of the machine - and ju... read more

How to Make Metal Dishes
How to Make Metal Dishes
Aug 07, 2008
OK, they're more dimples than circles, but Kevin needs to make 21 of them for a project. Watch as he... read more

How to Use a Plasma Cutter While Creating a Metal Sculpture
How to Use a Plasma Cutter While Creating a Metal Sculpture
May 30, 2008
Kevin shows - and explains - how a plasma cutter works as he begins a new stainless steel sculpture.... read more