Power tools for HGV maintenance and fabrication
A commercial vehicle workshop uses power tools differently from a general trade workshop. Angle grinders are essential for weld preparation, cutting exhaust components, and removing seized or corroded fixings. Reciprocating saws handle body panel work, rubber sealing removal, and cutting out corroded sections on trailers and body frames. Heavy-duty drills with percussion modes are needed for bracket installation and anchorage work on chassis and body panels.
When selecting an angle grinder for HGV and trailer work, disc size matters. A 115mm grinder is suitable for light fabrication and weld clean-up, but for cutting through chassis members, trailer floor sections, or heavy-gauge steel, a 230mm grinder with a cutting disc rated for the material is faster and safer. Always use the correct disc type — grinding discs are not rated for cutting, and cutting discs are not designed for grinding. Using the wrong disc type is a cause of disc failure.
For cordless tools, battery platform compatibility across your tool inventory reduces the number of chargers and battery packs you carry. If your workshop already uses a specific battery platform, extending within that ecosystem is more practical than maintaining two systems.
When using power tools on a commercial vehicle, take into account proximity to fuel lines, hydraulic hoses, and air brake components. Sparks from grinding or cutting near a diesel fuel line or a pressurised air system are a serious fire and injury risk.
Frequently Asked Questions
What angle grinder size is best for HGV workshop use?
For most HGV workshop tasks — weld clean-up, rust removal, and light cutting — a 115mm angle grinder is versatile and easy to handle in confined spaces. For cutting through heavy structural steel, trailer floor panels, or exhaust mounting flanges, a 230mm grinder is more practical. Many workshops keep both sizes.
What is the difference between a grinding disc and a cutting disc?
Grinding discs are thick and designed to remove material from a surface at a shallow angle. Cutting discs are thin and designed to cut through material perpendicularly. Using a cutting disc at a grinding angle can cause it to shatter. Using a grinding disc to cut is inefficient and can overload the disc. Always select the correct disc for the operation.
Are cordless power tools suitable for heavy workshop use?
Modern high-voltage cordless platforms (18V–54V) deliver performance comparable to corded tools for most workshop tasks. Battery run time can be a limitation on extended grinding or cutting work. For tasks requiring sustained power output over long periods, corded tools remain more reliable. Most commercial vehicle workshops use a mix of both.
What safety checks should I carry out before using power tools near a vehicle?
Check that the power tool disc or blade is rated for the material and is within its service life. Remove or protect fuel lines, air hoses, and hydraulic lines from sparks and heat. Ensure the vehicle is stable and safe before working under or around it. Wear appropriate PPE including eye protection, hearing protection, and if grinding, a face shield in addition to safety glasses.
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