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Kutzall Extreme – Very Coarse Coating Review

A first hand look at the new Kutzall Extreme – Very Coarse, Dish Wheel!

AVAILABLE DECEMBER 1ST

We had Lee LaVanway test out the new and improved Extreme – Very Coarse coating for himself. Read his in-depth review on his process and what he was looking for in our new coating:

 My Process:

‘When Kutzall queried my thoughts after selecting me at random for its new Kutzall Extreme – Very Coarse Dish Wheel,  I was happy because I am constantly on the lookout for more efficient tools to safely shape wood.

For me, safety is the most important thing and controls my processes as a “speed carver”.  I believe speed (RPM’s), is the key, not power (amps). I definitely do not consider myself a power carver. Speed allows the tool to do the work, and it seems to me that’s the safest way to use a spinning tool.

Still, I wear a long leather apron, heavyweight canvas shirt, safety glasses behind a full-face shield, and anti-vibration gloves, if there truly is such a thing…

To keep dust at bay, I do my roughing work outside, in front of a 30” industrial-duty fan on high speed, and with an N-95 particle mask over my mouth and nose. Without the fan, I would have to wear a hot respirator, though when it’s cool outside, I often do just that, nonetheless.

I use a powerful clamp, 37” long, mounted on a heavy steel frame as my work-piece holder. It makes for a rock-solid and easily positioned work-piece. I make it a mandatory practice never to allow a spinning tool to operate near the clamp, so I position the work-piece a lot. (This rule also allows me to take a little breather from the flow state of making art, which can often cause over exertion.)

My Experience: 

Over my lifetime, I have used chain saws, adzes, axes, coarse (and expensive!) rasps, and large mallet gouges, to advantage during roughing, and on occasion, I still use these tools.

Nevertheless, so far, nothing beats the Dish Wheel for rapid, controlled wood removal. The Dish Wheel is simply the best roughing tool I have ever touched to wood. Spinning at 11,000 RPM on the spindle of my 7-AMP  4 & ½” angle grinder, this tool takes as little or as much wood per pass as I desire to take. Granted, I do not desire to remove massive amounts of wood in a hurry. I prefer to make controlled cuts along the curves I designed for the finished piece, either a wall hanging or a freestanding 3-D sculpture.

I have no doubt that a more powerful angle grinder could increase removal dramatically during roughing. Yet for me, I like to take my time and get it right and get it done. Roughing is the dirtiest thing I do, but getting it right is more important than getting it done quickly. My main goal is to escape injury during the process, as roughing is also the most dangerous work I do. Happily, I remain injury free after almost 50 years of sculpting wood.

My Review: 

As a wood artist, I am keenly aware of the adage told to me by a master of stone sculpture who said, “you can take it off, but you can’t put it back.” It seems so obvious, yet the emotional impact of too much removal will drain away inspiration like pulling the plug in a bathtub. I know the feeling too well...

Thus, this tool allows for controlled removal, and that is what I need, and what I want in any tool. Being too aggressive on one-of-kind chunks of highly-figured hardwood isn’t worth the risk. The adage above, after all, is true, “…you can’t put it back.”

Make no mistake however; attached even to a six or seven amp angle grinder weighing in at only four pounds or less, the work this wheel does requires focus and a constantly firm grip. It is not a toy. But man, it sure lifts creativity up to a whole new level of inspiring possibilities.

I also own other Kutzall dish wheels; they represented real innovation when I bought those years ago and I still use them when the task calls for their specific advantage. However, the Dish Wheel takes the innovation beyond anything else I have used.

For example, I really appreciate how Kutzall’s new design further reinforced each individual carbide tooth: With the base of every tooth widened significantly from the new design, tooth wear and breakage should be minimal. Still, as with any high RPM tool, it is always best to let the tool do the work and not be too aggressive.

Finally, I have found from many pounds of chips on the ground that the wheels work best when they lightly touch down on the wood surface, and then lifted off while in motion laterally, like a small airplane landing and taking off, landing and taking off, etc.   It seems to me the ability to use a light touch while simultaneously removing the amount of wood I want to remove is what makes these tools so extraordinary.  

Kudos to Kutzall for continuing to innovate and lead the field among “speed carving” tool makers.

Want to test one out for yourself? Starting December 1st, you can visit the shop and pick up your own Extreme – Very Coarse coating tool!

Kutzall Shaping Dishes and Discs Just Got More Extreme!

Introducing the new and improved Extreme – Very Coarse coating!

AVAILABLE NOW

If there are two things we pride ourselves on, it’s the level of care and quality put into each and every one of our tools and the passion and excitement of our customer’s feedback. We took everything that you loved about our Extreme – Very Coarse Shaping Dishes and Discs and made them so. much. better.

Our products have always lead the industry in removing stock quicker and lasting longer than the competition. So, how do you make an already-impressive product even better? Keep on reading and you'll see how we turned up their performance a notch or two.

The new Kutzall Extreme – Very Coarse coating’s teeth have been improved to make them stronger, more stable and even more aggressive than before!  


  1. Strength - First, each individual tooth’s base diameter has been increased by 70% making the tooth structure more stable and able to handle even the toughest projects.
  2. Efficiency - Next the teeth are 50% taller for even more aggressive stock removal.
  3. Durability - Finally, the angle of the teeth has been increased by 5° to extend our wear-life even further.

     

    These tooth structure changes have opened up a world of carving capabilities. Not convinced? We recently put this tool into the hands of Lee LaVanway, an experienced craftsman and speed carver. These are a few of the highlights from his review on our new coating and the possibilities it holds for leaving your own unique mark:

    -"...nothing beats the Kutzall Wheel for rapid, controlled wood removal..simply
    the best roughing tool I have ever touched to wood."


    -"...it sure lifts creativity up to a whole new level of
    inspiring possibilities
    ."


    -"...the Dish Wheel takes the innovation beyond anything else I have used."


    -"Kudos to Kutzall for continuing to innovate and lead the field among
    'speed carving' tools makers."

    If you'd like to read the rest of Lee LaVanway's detailed review of the improved Extreme – Very Coarse coating you can find it here!

    With these new changes, the Extreme – Very Coarse Shaping Dishes and Discs are the toughest and most efficient tools on the market! This new generation of Extreme – Very Coarse tools is available now, so click below to experience this new coating for yourself and take your work to new extremes!

    Shop Extreme!

    Social Spotlight: Top 3 Spring Creations 2k16

    The finest creations from our followers

    Kutzall's Social Spotlight is our new seasonal segment where we highlight the top creations that our customers have shared with us via social media. This spring we've been tagged on numerous projects from our customers and below we're showcasing our top 3 favorite creations.


    Craftsman: Nik Drake - Sculptured Gardens

    Build: Log Mushrooms

    Tools Used: Kutzall 4.5" Sanding Disc


    Craftsman: Josh Dawley - Str8 Edge Construction

    Build: Mesquite Mini Longboard and 60's Retro Chair Restore

    Tools Used: Kutzall 4.5" Extreme Dish Wheel


    Craftsman: Marc Lamonthe - Toutanbwa

    Build: Rustic Wood Vessel Sink

    Tools Used: Kutzall 4.5" Dish Wheel

    We'd also like to showcase this awesome video marc produced showing his process.











    We love seeing what fellow craftsmen and Kutzall advocates are working on, so follow us on our social channels (links below) and tag Kutzall or use #Kutzall when you post a project. You could get featured in our Social Spotlight segment!

               

    KUTZALL HAND RASPS REVIEW: CANADIAN WOODWORKING & HOME IMPROVEMENT MAGAZINE

    Our revolutionary Hand Rasps, were recently featured in a Canadian Woodworking & Home Improvement Magazine review! Check it out here!

    I found that the Kutzall rasps worked exceptionally well, whether cutting with or against the grain, in any direction. They're ideal when you need to smooth tight curves, particularly on highly figured stock, and they leave a surface that doesn't take a lot of time and effort to smooth with card scraper or sandpaper.
    -Carl Duguay

    If you want to experience the controlled, multi-directional carving ability of our innovative Hand Rasps for yourself, you can find them here! Our Hand Rasps are available in a variety of different coatings and sizes and will allow you to precisely carve and contour areas that rotary carving tools simply cannot reach.

     

    To learn more about or shop our selection of Hand Rasps, click here!

    Caring for your Kutzall

    The complete guide to maintaining your tools!

    Thanks to our exclusive coatings and unparalleled quality of materials, Kutzall tools are acclaimed for staying cleaner and lasting longer than their traditional counterparts. But, like every well-used tool, eventually it will need maintenance.

    If your tool, whether it’s a Burr, Sanding Disc, Dish Wheel or Hand Rasp, has accumulated too much medium in its teeth and it’s affecting your carving performance, you may need to give it a thorough cleaning.

    Not to worry, cleaning and caring for your Kutzall is an easy, straightforward process. Depending on the medium you’re carving there are two ways to clean your tool.


    Option 1: Burning (for wood only)

    What you'll need: A well used Kutzall tool, butane or propane torch, fine hand wire brush, dusk mask or respirator, leather gloves, eye protection, water or a fire extinguisher on standby for safety.

    1. Set-up in a well ventilated area.
    2. Unplug the power source and remove your Kutzall from the power tool.
    3. Ignite your butane or propane torch, and slowly pass the flame over the built up material until it burns and hardens to brittle char.
    4. Using the hand wire brush, scrape away any excess buildup that's caught in the teeth.
    5. Repeat burning and brushing as many times as necessary until the teeth are free of debris.
    6. Allow the tool to slowly cool down to room temperature (do not quench in cold water immediately after burning).
    7. Inspect the tool for excessive wear, broken teeth, etc. (replace if necessary)
    8. Reattach to your power tool.
    9. Carve on!

    Option 2: Soaking (Recommended for wood, stone, plastics, and composites)

    What you'll need: A well-used Kutzall tool, solvent capable of breaking down your clogged material (mineral spirits, turpentine, or acetone work well), large glass container, fine wire brush, dusk mask or respirator, leather gloves, eye protection.

    1. Unplug the power source and remove your Kutzall from the power tool.
    2. Fill a large glass container with your solvent of choice in a well ventilated area.
    3. Submerge the clogged part of your Kutzall tool in the solvent (Note: do not submerge the rubber handle of a Kutzall hand rasp).
    4. Allow the solvent adequate time to soak into and penetrate the built up material. This can take several hours.
    5. Remove the soaked tool from the container and firmly scrape the clogged material away with the wire brush.
    6. Repeat soaking and scraping as many times as necessary until the teeth are free of debris.
    7. Wash the solvent off of your tool using soap and water and dry thoroughly.
    8. Inspect the tool for excessive wear, broken teeth, etc. (replace if necessary).
    9. Reattach to your power tool.
    10. Carve on!

    We hope this article has provided you with some clarity on how to properly clean and care for your Kutzall. If you have any questions, please feel free to post them in the comments below and we'll do our very best to answer them!

    Kutzall Perfect Pairings

    To make it easier for you to select the ideal power tool to use with your Kutzall Sanding Discs & Dish Wheels, or with Kutzall Burrs, we have assembled this list of recommended tools shown (below).

    The recommendations list is drawn from some of the top power-tool manufacturers in each class of machines reviewed. These are manufacturers whose tools we have found from personal use to be of high quality, with attractive feature sets. Most are also brands generally found to be favored for quality and performance among serious tool-using professionals and craftsmen, in a wide variety of fields.

    Without further ado, here is our recommended "Perfect Pairings" list!

    Dish Wheels & Sanding Discs 


    4.5" Models

    7" Models

    1/4” Burrs


    1/8" Burrs


    *1/8" collet included or optional

    In selecting a grinder, there are a number of very individualized, personal-preference decisions you will likely have to make. Specific preferences can stem from your previous experience with power tools, the type of projects you plan to work on, etc. Below are listed some factors for your consideration when electing many of the tool types listed. Most of these apply both to the choice of an angle grinder for use with Kutzall Dish and Disc Wheels, and for various rotary tools for use with Kutzall Burrs.

    On-switch design.

    There are several types of on-off switches on electrically-powered grinders. The type listed below are commonly found on angle grinders and many rotary grinders.

    Slide switches: With a slide switch, the slider button moves fore and aft, and is often toggled with the thumb. Switches commonly are positioned on the side of the power tool, but also sometimes on the top. Slide switches feel pretty natural to manipulate from the normal operating hand position on the tool for many people, but a few find the position requires changing their grip position before activating or deactivating the switch.

    Paddle switches: Paddle switches are typically wide, paddle shaped levers, most often on the underside of the tool at midsection, which can be operated with one or more fingers. They can be activated with your hands in the normal operating position on the tool.

    Trigger switches: Trigger switches are much like the trigger on your power drill. They usually are mounted toward the rear of the tool, and are activated with the index finger.

    Making a choice between these options is a very personal thing. Ideally, you can visit a merchant with a wide selection of tools, and manipulate different styles in your hands to see what feels best.

    In addition to the above-mentioned switch types, certain specialty rotary grinders, such as the flex-shat tools, usually are used with a foot switch. This has obvious advantages from the standpoint of being able to toggle the grinder on and off, while having both hands free.

    Lock on vs. non-lock-on switches

    Within the variety of switch styles listed above, you also have the choice of locking or non-locking switches. A non-locking switch is like the gas pedal on your car, it only works when pressed. A locking switch is more like a car with cruise control, it has a button or other feature which allow the switch, once engaged to “on,” to remain in the on position, without constant finger pressure.

    Again, the choice between the locking and non-locking switch design can be very personal. Some like the confidence-inspiring feel of a switch which can be immediately released to off when finger pressure is removed (think of how you like to be able to stop your drill immediately if a bit binds in a hole). Other users want to be able to manipulate their grip on the tool, or otherwise reposition their hands during use, and find a non-locking switch to be a constant annoyance.

    Fixed-speed vs. variable-speed

    While many grinders run at a fixed speed on household current, others have adjustable speed. The adjustable-speed option is another of those factors which are more or less attractive, depending on your work and personal preference. In general, those looking for the greatest flexibility and versatility across a wide range of projects will prefer the variable-speed option.

    Soft-start option

    Some grinders come with a soft-start feature, so that the tool scrolls up to full speed gradually. The soft-start feature is not as useful with Kutzall tools as it might be with, for example, buffing wood or metals with polish. However, some find the gentle start-up feature comforting.

    Horsepower/Amp rating

    The power rating of a tool is an important indicator of how much work you can do with the tool in a given amount of time, i.e., “how hard can you work it?” Although different manufacturer’s tools show different weight penalties for greater power, other things being equal, you will generally end up with a heavier tool if you opt for more horsepower (a higher amp rating). For those working on large pieces, or with a lot of material to remove by grinding, a higher-power tool is probably the best choice. On the other hand, for those doing more detailed or smaller work, or expecting to have to handle the tool steadily for longer periods of time, a lighter-weight tool, even of lesser power might be a smarter choice.

    Cordless/corded options

    Many DIY-types like cordless tools for their convenience around the house and garage. It has been our experience, though, that wood carvers and other craftsmen usually prefer the steady and reliable power output of corded tools. Most hobbyists and craftsmen have a fixed location that they usually work in, like a home workshop.

    Issues specific to angle grinders

    In addition to the general power tool attributes mentioned above, angle grinders have some specific areas to examine.

    The first consideration on angle grinders is the spindle design. Most modern angle grinders sold in North America have a 5/8-11 threaded shaft. These typically come with a set of nuts or a nut and backing plate with 7/8” diameter shoulders for mounting accessories. The Kutzall Sanding Disc and Dish wheels have a 7/8” inside (arbor-hole) diameter, and mount onto these accessory mounting components. Please note that mounting a Kutzall Sanding Disc to the accessory adapters supplied with your grinder can sometimes require inverting one of the components. There are special, third-party stacking adapters available to allow mounting 7/8” I.D. accessories like a Kutzall Sanding Disc or Dish Wheel to older designs with a 3/8-24 threaded shaft.

    Another consideration is that angle grinders can come with additional features which might be desirable to you.

    Some angle grinders have a clutch mechanism in the head. This is intended to let the motor spin free if the tool accessory should bind or lock-up in a workpiece. The feature protects the gear-train from damage in a hard-stall situation.

    Angle grinders can also be found with a braking feature, so that when the on switch is released, the grinder stops rotating very quickly. This, of course, is intended as a safety feature.

    If these features are attractive to you, look for a grinder which offers them. Bear in mind, though, that added features might meant added cost, and added weight.

    Issues specific to die grinders

    While die grinders were conceived for the metal-working field, they offer a lot of power in a package that many craftsmen like for wood carving and similar tasks when using rotary burrs. Die grinders typically come with a ¼” shaft collet, and thus can use rather large rotary burrs for big jobs. The die grinders in the recommendations list all feature the ¼” collet, which works with the ¼” shaft size Kutzall Burrs. Some have an included reducer bushing, so that you can also use the smaller, 1/8” shaft size Kutzall Burrs. Even for those grinders not offering this included accessory, it is often possible to buy a sleeve or accessory collet which would allow for the use of 1/8” shaft burrs.

    Die grinders can be had with somewhat greater power and physical size that those recommended here. Our recommendations are based on the lighter-duty usage that customers most often experience when wood carving. The really heavy die grinders are probably more suitable for ironworkers, or others who require a lot of power for intermittent, high-load applications, and are willing to deal with the much higher tool weight.

    Issues specific to rotary grinders

    “Rotary grinder” is a very broad term. Here we use it specifically to refer only to small electric hand grinders. Some might be marketed directly to woodcarvers, while others are often advertised as a do-anything household DIY tool. These can usually be easily balanced and maneuvered with just one hand, while manipulating the work piece in the other hand, and are very good for fine detailing work. Their overall size might be compared to a small to medium-sized banana, although some can be as small as a dental hand-piece. These are all pretty small as compared to die grinders, which are generally much larger and more powerful.

    The primary attributes to consider on a rotary grinder are its size and manipulability, as well as the size tools it accommodates. For the smaller Kutzall Burrs, you want a tool with a 1/8” shaft collet. The rotary grinders are not normally able to handle tools with larger shaft sizes than 1/8”

    Issues specific to flex-shaft tools

    While the majority of flex-shaft tools are perhaps applied in the jewelry-making field, a great many carvers prefer flex this style of tool for their rotary-tool needs as well. With a flex-shaft tool, the motor hangs on a hook or other fixed support, and powers a covered flexible shaft, which connects to a rotary-tool hand piece. Flex-shaft tools have some significant advantages for many users. For one thing, the user pays no fatigue penalty for using a rather powerful machine, as the motor is supported by its support and not by the operator. The hand-piece, then, can be rather small, allowing for deft manipulation when doing very detailed work. Most grinder manufacturers offer a number of hand pieces, so the size and type of rotary burr or bit, and the accessibility to different kinds of work-pieces, are highly adjustable with the use of accessory hand-pieces. Possible the most limiting factor with a flex-shaft tool is the fixed length of the flex-shaft. One would not work over as large a physical area or work piece with a flex-shaft tool as could be done with the other types of tools discussed here.

    As with all power tools, don’t forget to use proper eye protection and safety devices at all times!

    Kutzall Tools On Ice: Bringing local ice sculptures to life!


    As our name implies, Kutzall tools are great for carving nearly all mediums. Recently, we had the chance to get put our name to the test and get our tools into the hands of some local ice carvers. Check out the video above to see the tools slice through ice and the reactions of a professional ice carver!

    To check out our professionally recommended ice carving tools, click the button below!

    Kutzall Hand Rasps Review: ScrollSaw Woodworking Magazine

    Our latest product, Kutzall Hand Rasps, were recently featured in a ScrollSaw Woodworking Magazine review! Check it out here!

    These tools, which come in a variety of shapes and grits, stand head and shoulders above traditional rasps, reaching areas many other tools will not.
    -Bob Duncan

    Whether you're trying to remove material quickly or smooth out less than perfect cuts, our Hand Rasps are the perfect solution. They're available in a variety of different coatings and sizes and will allow you to perform precise, multidirectional cuts and carve out tight areas that rotary carving tools simply cannot reach.

    To learn more about or shop our selection of Hand Rasps, click here!

    Decem-Burr: 10 Creative Uses for Kutzall Burrs

    Kutzall burrs are the perfect carving tools for challenging jobs. Our burrs are made with incredibly durable materials like tungsten-carbide, provide effortless and efficiently smooth carves, leave behind a beautiful surface finish, and are designed to resist loading. With a Kutzall Burr, you spend more time creating and less time maintaining.

    Since it's December, we figured it's the perfect month to elaborate on our burrs. You see, Dece is latin for 10 and then there's the obvious "ber"= "burr" pun! 

    • The BN-34, 1/4" Ball Nose Burr is perfect for free floating a barrel on a gun stock to improve accuracy
    • The T-18-E, 1/8" Taper Burr makes tracing text on a wooden sign a quick effort with "pencil-tip-like" precision
    • 1/4" Taper and Flame Burrs are perfect for carving scale and feather textures into wooden duck and fish sculptures
    • Hollow Log Tree Carvers will find the 1/4" Flame and Sphere Burrs incredibly useful at removing material and carving intricacies on their log sculptures. 
    • Course Ball Nose and Flame Burrs in both 1/4" and 1/8" shaft diameters are a must have tools for Ice Carvers
    • If you're looking to notch out a section in drywall, try using the Rotor Saw Burr for efficient, smooth and controlled cuts.
    • 1/4" Dovetail Burrs are good for carving fur texture on animal sculptures
    • No matter your medium, Cylinder Burrs are perfect for removing serious amounts of material and leaving behind a level, uniform surface. Fish Carvers will find this tool incredibly useful on fins.
    • 1/8" Flame Burrs with a fine coating are perfect for stipple engravings on glass.

    We hope that this list has given you some creative ideas on how to use your Kutzall Burrs. If you have another creative use for your Kutzall Burrs, we'd love to hear about it; share it with us in the comments below or on our Facebook page! If you're looking to expand your burr collection, shop our complete line of rotary carving burrs today

    Kutzall Hand Rasp Review by: Woodcarving Illustrated

    "Kutzall Grit Hand Rasps bring the convenience of power carving to hand carvers."

    Kutzall’s Hand Rasps are an essential tool for any carver. Whether you’re shaving material from intricate areas or hand carving free-form curves, Kutzall’s Hand Rasps will give you the precision you need to get the job done. What separates us from other hand rasps? The review of Kutzall’s Hand Rasps from Woodcarving Illustrated Magazine answers that question.

    Kutzall Hand Rasps by Woodcarving Illustrated