Looking for some good recommendations for rotary tools. I bought a Dremel 400 xpr a long while back, killed it, dremel replaced it for free and then I shortly killed that one.

While a few searches reveal similar horror stories with that particular model, I do think it had fair bit to do with my just beating the thing to death. I usually don't abuse equipment, but I got the impression that while it didn't need to be babied, it did need to be cooled occasionally and you might have to stop in the middle of something. Well, I'm just not that patient.

So before I drop 50 bucks on a similar low amp model, has anyone here had particular luck with a heavy duty model? Could be something for me to put on the Christmas list.

It sounds like you've got two problems. First is that you are not respecting the limits of your tools due to impatience. A lot of working well involved working within the limits of your tools and materials. You may want to stop and think about that now and then. Second it sounds like you're trying to get die grinder performance out of a light duty 1/8 shank tool.

You could pay for one of the more costly Dremels and you'll find that they last longer. They make this stuff to a price point and you can't get $100+ performance and longevity from a $50 tool.

But having said that you still need to realize that any Dremel is a light duty tool. Even their good ones are not up to the sort of hard use that a Foredom or a die grinder will tolerate. Even the Foredom is more of a middle ground between the Dremel and a proper die grinder. If you're trying to dig and hog into the metal with either Dremels or Foredoms becuase you have little patience then you need to switch to a 1/4 inch die grinder that is either air or electric. An electric die grinder is like a Dremel on steroids. Most of them will stand up to heavy use that will cripple a Dremel in minutes. Then the Dremel or Foredom is used for the final lighter detailing and finishing.

But a decent electric die grinder isn't cheap. If you're complaining about the $50 Dremel because that's all you want to spend then you're sort of dead in the water already. Electric die grinders seem to start at around $130 for a Bosch unit I found online and go up to the mid $300 region.

It really is a question of money or time. Nothing you'll get from Dremel or anyone else for well under $100 is going to have a lot of resistance to hard, long term use fueled by impatience. But slow down, let the tool cool now and then and use it so that you're not dragging down the speed a lot and you can do the work with a $50 tool just fine. Your choice.

Dremels are not quality power tools and they're not good about keeping parts for older models in stock. I had to throw one away last week because a repair part is no longer available. Do some searches for Proxxon of Germany. They make high quality tools and they sell for just a bit more than Dremel.

My Dremel tool died too. It wasn't a matter of abusing it. It was a matter of it being a cheaply built tool. For a replacement I purchased a rotary tool from Harbor Freight. It was cheap and when it dies I will not be out much (approx. $25). I have used it for a couple of years now and have been very happy with its performance.

Flexible shaft tools allow a much larger Motor to be used, but they are mounted above a bench.
not handheld. you manipulate the end of the flex shaft.
https://www.foredom.net/

The driveshaft on my dremel was a piece of plastic tubing. Two of those failed. The variable speed switch went bad and the only way to turn it off was to pull the plug. What makes me mad is that I have a Dremel flex shaft, drill press and router attachment that won't fit the Proxxon I want to buy.

I don't think anybody wants to spend that much for a tool for bicycle applications.

then How about Hand files? OK they require patience. ..

Air compressor and Chicago Pneumatic die grinder and other air tools. You can screw up a lot of metal with those!

What kind of stuff are you doing? I've had Dremels that lasted for 10-years+. Then I went to air-tools for heavier-duty work. Then finally got one of these:

I've been using a die grinder and cut off tool since the Dremel died. They're a bit too powerful for some jobs and hearing protection is mandatory.

I'm sure it was at least ten years old, but it was lightly used.

Some clarification, I did not say I wanted a 50 dollar tool to perform better than another 50 dollar tool. I'm wiling to spend good money for something more heavy duty.

Also, I said I was impatient more in jest than anything. I used it once to cut some fiberglass and carbon fiber molds. Another time I cut a small metal clip from a motorcycle frame and the last time I was simply grinding down a chain link on said motorcycle to remove the old chain. (You have to sand those suckers down before you can puch out the rivet link). None of these were what I considered to be heavy duty, yet the dremel failed. I was pretty disappointed. I actually dropped 70-80 bucks on what was then their top of the line model.

They were nice enough to send a second, but I used it for a few quick jobs and it lasted maybe 30 minutes total. I made a point of letting it cool then, but it still failed.

Simply put, I don't generally abuse tools, as I previously mentioned, but when I spend 70-80 bucks, I expect something to last more than 5 or 6 uses. I might as well pay somebody 15 bucks each time I need dremel work than buy another. What I'm looking for is a good electric rotary tool that WORKS and isn't junk.

As for all the other suggestions, thanks, I'll look those up.

OK on that clarification. Sorry if it sounded like I got into a rant.

Sadly Dremels and other smaller rotary tools of the same type just are not as all powerful as the ads on TV would have you believe. The stuff you used your tool for SHOULD have been within their ability but perhaps they just don't make 'em like they used to. I've got an old model 350 that has been working well for about 25 years now and is still going strong. But it mostly gets used for work on model airplanes. And balsa isn't as hard to work as a pin on a motorcycle chain. If it helps any the tool of choice for jobs of that sort would be more in the way of a 4 inch angle grinder. The Dremel would do it but it would be a long and painful process.

Anyhow best of luck with whatever you get as a replacement.

Flexible shaft tools is the better choice!

Flexible shaft tools are sure to be nice choices.

+1 on the Harbor Freight Models. We had a dremel in the shop I worked at the lasted for years so I was really happy when I went to purchase my own. Didn't use it much so I was real displeased when it broke on the 8 time I used it. On the other hand my Harbor Freight, which was 20 on sale is still going after 5 years. Plus you can keep spares. For heavy work I pull out the air die grinder.