In another thread, members helped me decide on the purchase of a rotary tool (Proxxon 38481 IBS/E ), and now I am asking your advice on proper accessories I will need for cutting and shaping copper bar stock 1/4” to 1” thick.
There are too many options on cutting bits, discs, materials, etc. for me to really know what I should be using. Help keep ouchyfoot safe by not letting him use the wrong accessories for the job at hand.
I have two new pairs of safety glasses.
Well, you have the first important piece, safety goggles. The next is a good dust mask. I use a P100 cartridge mask for any dust generating activity. No chances need to be taken.
The mask and two filters can be found for around $25-30 in HD or any hardware store. The (pinkish-red) cartridges last quite a while.
The lower cost alternative is N95 face masks. These are the white fiber masks. I dislike them because I can not get a good face seal.
Tools themselves, I use the metal cutting discs and the various grinding wheels. Sanding drums and pads are good too. For polishing, I use a buffing wheel and the compound. You can get kits for $25 or so that come with all the goods. Home hardware had a Dremel brand one on sale a few weeks ago that got me through the DIY build; lots of cutting and grinding. 
Cutting 1” bar stock will be better off done with a hacksaw, then shape with grinders. Thinner stock will cut with the Proxxon.
Wear a leather glove to hold the stock; copper heats up fast 
I predict that no matter what selection of tooling you have, you will quickly come to absolutely loathe doing anything to copper with power tools. Copper eats everything.
How is that?
It can go from cutting fine one minute to smearing and grabbing and breaking off drills with no warning. Same with end mills or lathe work. It's just miserable stuff to work with. Aluminum and brass are a joy in comparison. Copper sucks.
I assume that would be the heat softening it.
No, copper is just notoriously difficult.
It’s good to see you have the eye protection. As an annoying middle aged deaf bastard, if its noisy with what your doing l’d highly recommend some descent hearing protection. The annoying part is people getting sick of you saying, whaaaaaaaaaat.
Copper is wonderful unless you have to machine it. Then it is a major PITA.
Yes, copper is much more difficult than brass. I know this now, after the DIY build
About the best way I could describe it, is its like trying to machine chewing gum. It sticks to cutting tools and gums up cutting edges. It has to be machined at slow speeds or flooded with coolant. Keeping oil on a hacksaw blade will greatly increase cutting speed and prevent galling. It will (gum up) stick to a grinding wheel in no time.
I had no galling when I cut lots of copper recently, but I did go quite slow. The cutoff wheels disappeared fast though.
Brass was like butter in comparison.
Grinding aluminum resulted in a grinding wheel coated in aluminum. Maybe I was going to fast with it or used the wrong wheel.
To grind aluminum you have to keep it cool. Take small grinds and dunk in water for a second or two.
If the aluminum gets to hot at the grinding surface, it melts to the wheel. If you need lots of material removed, its better to machine it.
Awesome tip, thanks! 
Ouchyfoot, these are suppose to remove copper well. I have never tried it so I can’t comment on how well it works.
http://www.amazon.com/dp/B0035YF6GG
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I have used them in aluminum and they remove material very well, a little to well if your not careful.
Here’s another source.
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The amazon burr set is a double cut. The grizzly burr set is a single cut.
You can find them individual on ebay for less if you just need one or two profiles. Just make sure it’s carbide and a 1/8” shank.
They will also grind steel very well too, just be careful with all the metal shivers. They can end up in your fingers (painful tiny metal splinters) and any where else they fall.
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If you need something a little different or for a specific purpose.
www.monstertool.com/Burr_Monster.pdf
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Never use them without eye protection. I use cheap safety glasses.
Oh I do wish that you hadn’t posted that MonsterTools link.
That’s going to cost me money that is! :bigsmile:
Try milling your copper under the influence of liquid nitrogen…