Best way to cut stock to size

[Ian S CParticipant @iansc]

I have a friend who managed to embed the window in his workshop with steel and grit from using an angle grinder. but worse than that a chap I was working with set fire to the crutch of his overalls while using an angle grinder, luckily no damage to the important parts, it was his wedding the next day. Use the angle grinder, and for the long cuts clamp a bit of steel along the line, and use this as a guide.

Ian S C

[BWParticipant @bw]

Posted by Muzzer on 20/12/2016 20:51:53:

Like Brian_G, I've heard good things about the Evolution Rage thingies. They are only(?) £100 and seem to be pretty effective. I'd consider one of them if I didn't have a band saw, particularly if I also played with The Brown Stuff.

Murray

I've been aware of these saws but never seen one

What thickness of solid round or square bar has it been known to cut ?

Bill

[Roger Williams 2Participant @rogerwilliams2]

Bill, ive the one with the 350 mm disc and have cut many 2 inch mild steel bars on it. Take it easy, and they will cut just about anything. Very noisy though. With some juggling, I cut through a 6 inch square RSJ the other day.

[AjohnwParticipant @ajohnw51620]

A horizontal band saw is probably the most flexible option. It doesn't care what the size of the metal is providing it fits within it's capacity. Having said that though I have turned bar and things like that over to exceed the usual 4" depth. Many of them can also be used vertically by adding a small metal table.

Buy one of these and you will put a lot of your cutting needs to bed in one go. There is a thread some where on here where some on complained about how poor the cheap chinese ones are. Replies metioned what usually needs to be done – blade tracking adjustment and the fact that the blade needs to be rather tight. They use a spring to provide the downward cutting force. That may need adjusting on larger bars at the beginning and the latter parts of the cut. It may not cut dead square but will get close enough for quick use of a file on things like angle iron.

Frankly I wouldn't be without mine and many owners feel the same. They will also cut timber ideally with a coarser blade.

Chop saws are sometimes used now. Noisy and I have no experience of them. I'd be surprised if a cheap one is as capable as the above.

Bandsaws that can stand up to metal cutting long term tend to be rather expensive. Lots of cheap ones use cheap flimsy die cast supports for the blade guides etc. I bought a dewalt eventually. That was just cutting timber. The metal cutting thickness is severely limited.

Personally I would avoid very cheap angle grinders. Following the death of my mother I needed to chop up a stair lift into 3 sections to get it into a van. I bought a cheapy as I didn't have mine with me. I suppose it was running and cutting for maybe 15mins. On the last cut it burnt out, fortunately when it was more or less through. Another tool I wouldn't be without. Buy a decent one if you go this way. The can also be fitted with grinding wheels that are used face on – not on the edge. Also scratch brushes.

The other option is a reciprocating saw. At our level that is often a home made one. The best design I have seen is by Myfordboy on youtube. You could cut up the sections needed with an angle grinder. He also uses a circular saw on plate etc. It's one specifically intended for cutting metal. That could be rigged up as a table saw pretty easily.

As I see it the options that don't make much noise and are very safe and easy to use are the horizontal bandsaw or the reciprocating one. I don't like noise either. Sparks – well make sure they are flying away from you and use the guard.

John

–

Edited By Ajohnw on 21/12/2016 10:18:03

[VicParticipant @vic]

I have a dual speed wood cutting bandsaw. I'm given to believe that if I put it in low speed it will cut aluminium alloy with a HSS blade. Anyone tried this? I'm wondering how long the blade will last!

[MikeParticipant @mike89748]

Just a question – is it possible to cut aluminium with an angle grinder, or does it clog the disc?

[TrevorhParticipant @trevorh]

You can get aluminium cutting discs for the 4" angle grinder- screwfix and other places

the 1mm ones are good for neat cutting but can and do flex

cheers

trevor

[JasonBModerator @jasonb]

Vic I have used my old Rexon woodcutting bandsaw on aluminium, this is a bit of 3" square cut with it. Also does brass & bronze

Though now I have got a Femi 782XL which is easier and will also work vertically with the additional table that is avalable.

Cut this 2" EN8 in just over 2mins

And some 2×5 CI was no problem

[Nicholas FarrParticipant @nicholasfarr14254]

Posted by Mike on 21/12/2016 11:26:15:

Just a question – is it possible to cut aluminium with an angle grinder, or does it clog the disc?

Hi Mike, you can cut aluminium with an angle grinder, but most everyday discs do tend to clog up a bit and the cut is not very smooth. To get a good cut, you need a disc for cutting or grinding that is designed for aluminium, especially if you intend to weld the edge that you are cutting/grinding, but they are a little dearer and not every retailer sells them. There are some at this **LINK**

Regards Nick.

[MikeParticipant @mike89748]

Thanks, guys. It's just that I have some 2 1/2-inch aluminium bar to cut into several pieces, and it's proving to be too tiring to hacksaw. A bandsaw would be ideal, but I don't have one – but I do have an angle grinder.

[Men IfrParticipant @menifr84251]

Does anyone have a link to the cheap chinese bandsaws as a good one is well out of my price range. What sort of price am I looking at?

[norman valentineParticipant @normanvalentine78682]

Not cutting but grinding. For aluminium, the discs designed for stone work without clogging.

[norman valentineParticipant @normanvalentine78682]

Despite all the arguments against angle grinders they are very convenient and cheap. I have used the cheapest from B&Q and yes, they are not great quality but at £20 they are great value. I bought one and used it for six months and it burnt out. I had kept the receipt so I took it back and was given a replacement. That too burnt out after a few more months. I took that back and as there were none in stock I was given a refund. So what is there to complain about? One years free use of an angle grinder. That seems good value to me.

[JasonBModerator @jasonb]

Posted by Men Ifr on 01/01/2017 22:50:04:
Does anyone have a link to the cheap chinese bandsaws as a good one is well out of my price range. What sort of price am I looking at?

Chester and Warco both do cheap ones, not used one myself so will leave that to others

[Anthony KnightsParticipant @anthonyknights16741]

I am currently on my third cheepo 115mm angle grinder in 15 years. I have still spent considerably less than I would have, had I bought what the purists would call a "proper" machine. Considering the amount of use it gets and the fact that I am in my 70's it would not make sense to splash out on a top of the range piece of kit. It would be different if I used it all the time.

I tried a "rage"saw blade but I found it noisier than the angle grinder.

Edited By Anthony Knights on 02/01/2017 09:20:15

[Nigel McBurney 1Participant @nigelmcburney1]

I always use angle grinders outside of my workshop,as the sparks and grit will cause lots of damage,my concrete apron outside the shed is a bit rust coloured,also keep any pets well out of the way as the flying grit can get in their eyes. Unless you are very strong and fit don't be temped to buy a big 9 inch grinder,they can be very dangerous particularly if cutting vertically ,had a couple of near misses one took a lump out of my trousers so its now at the back of the cupboard, they are safer when used horizontally at chest level with a grinding disc,its the cutting discs that can jam and jump out of the work.

[Gordon WParticipant @gordonw]

I've been using angle grinders for many years, maybe since they first came out. They can be dangerous, same as anything else. I've burnt a few jumpers and trouser crotches. When I was cutting up lots of steel for gates etc. I built a stand to fit the 9" grinder and used it for years with no problems.I use 4" & 41/2" ones now, mostly. The 41/2" with thin cutting blades are great. 9" for cutting bigger stuff, including sheet steel up to about 1/2". Price- I worked out that cheap ones that last about 6 months, everyday use, work out cheaper than a top-of-the-range one, but my 4" is a top price and I like it. The expensive ones are lighter and easier to use. Safety- always use eye protection, keep out of line with the blade, never use when tired. Don't use if you don't feel happy with it. Same as any tool, eg. chain saw, grass cutter, step ladder. BTW stone cutting discs can be used and may be better for softer metals, a lot of the scrap boys use them.

[AjohnwParticipant @ajohnw51620]

Posted by JasonB on 02/01/2017 07:28:20:

Posted by Men Ifr on 01/01/2017 22:50:04:
Does anyone have a link to the cheap chinese bandsaws as a good one is well out of my price range. What sort of price am I looking at?

Chester and Warco both do cheap ones, not used one myself so will leave that to others

The one that is still about that looks like mine is this one. Somebody somewhere usually undercuts Machinemart.

**LINK**

Looks like draper and sealy are selling the same sort of thing for more. Jason' is near £400.

I'd guess that the cheaper ones are ok when adjusted correctly but may loose out on using an AC motor. Mine hasn't done a colossal amount of work and is probably 20 years old now. Some people have cut lots with them. The stand is flimsy but does it's job. I wont be changing the one on mine except when and if it rusts through. It's spent it's life in a damp garage. It doesn't look nice now but still works.

John

–

[MWParticipant @mw27036]

I would personally conclude from this, the cleanest, most efficient and cheapest way to get through stock without hand tools has to be a D.I.Y metal cutting bandsaw. They have a proven track record of being able to cut through the vast majority of materials, in sizes under 6" in a reasonable amount of time, without hitting the wallet too hard.

There are also plenty of modifications you can do to them, which have been run through this magazine, and you can look at some of them on mike cox's website.

PS. their biggest downside seems to be their large footprint, you can use them without the metal framework and simply mount the cast iron table on a workbench, I think if it doesn't fit in your workshop, you could always put it in your garage if you've got one.

Michael W

Edited By Michael-w on 02/01/2017 13:11:56

[Carl Wilson 4Participant @carlwilson4]

Posted by Michael-w on 02/01/2017 13:01:53:

I would personally conclude from this, the cleanest, most efficient and cheapest way to get through stock without hand tools has to be a D.I.Y metal cutting bandsaw. They have a proven track record of being able to cut through the vast majority of materials, in sizes under 6" in a reasonable amount of time, without hitting the wallet too hard.

There are also plenty of modifications you can do to them, which have been run through this magazine, and you can look at some of them on mike cox's website.

PS. their biggest downside seems to be their large footprint, you can use them without the metal framework and simply mount the cast iron table on a workbench, I think if it doesn't fit in your workshop, you could always put it in your garage if you've got one.

Michael W

Edited By Michael-w on 02/01/2017 13:11:56

You'd be right.

[AjohnwParticipant @ajohnw51620]

Footprint was mentioned to me. I went to a model engineering supplier in Peterborough to buy a couple of things. One of them was a diy kit for a reciprocating saw. He had them in stock and asked if I had much space. Yes for that so he told me to buy one of the cheap horizontal ones. It was what he used for cutting stuff up for his kits. He did point out that the length stop doesn't work well – he was entirely correct too.

That seems to be the choice on a budget. Either the band saw or a diy reciprocating one. Rather than the usual ME designs I'd suggest the Myfordboy one that can be found on youtube. That one seems to work extremely well and I doubt if it's expensive or difficult to build.

Bound to need a hacksaw though or any of the other ideas. I have cut stuff with an angle grinder at times. Usually thin stuff. It takes time. If I needed to cut stuff that wouldn't fit in the bandsaw often I would probably buy one of the metal cutting circular saws. Myfordboy demo's the use of one of those in one of his video's. Think it's on a some metal rolls that didn't work out as good as his own design.

John

–

[JasonBModerator @jasonb]

Posted by Ajohnw on 02/01/2017 17:28:23:

If I needed to cut stuff that wouldn't fit in the bandsaw often I would probably buy one of the metal cutting circular saws.

Wot, not going to use your new plasma cutter?

[AjohnwParticipant @ajohnw51620]

Posted by JasonB on 02/01/2017 17:43:25:

Posted by Ajohnw on 02/01/2017 17:28:23:

If I needed to cut stuff that wouldn't fit in the bandsaw often I would probably buy one of the metal cutting circular saws.

Wot, not going to use your new plasma cutter?

I didn't think that the suggestion of buying a plasma cutter would go down well Jason.

Also no idea how long the one I have bought will last or how thick it can go neatly. I've been wondering where I could get some cheap boiler plate from to practice on – once the pneumatics are sorted. I may finish up grafting a clark twin head pump onto the the compressor. That's the sort of thing I'd only probably do when I needed to plasma cut.

Kitchen willing I should be able to see if the compressor will supply enough air next week if I get the fittings this week. I can play around while kitchen things are drying. Actually cutting something is likely to take longer. I suspect that I would be wasting my time without something to set the spacing from torch to metal. seems that the need to be 1mm away. I've no idea so have to assume that's correct.

John

=

[MWParticipant @mw27036]

Posted by Ajohnw on 02/01/2017 17:28:23:

Rather than the usual ME designs I'd suggest the Myfordboy one that can be found on youtube. That one seems to work extremely well and I doubt if it's expensive or difficult to build.

Bound to need a hacksaw though or any of the other ideas. I have cut stuff with an angle grinder at times. Usually thin stuff. It takes time. If I needed to cut stuff that wouldn't fit in the bandsaw often I would probably buy one of the metal cutting circular saws. Myfordboy demo's the use of one of those in one of his video's. Think it's on a some metal rolls that didn't work out as good as his own design.

John

–

I have seen the myfordboy auto-hacksaw design, and even a few castings for sale to help you make one, it would be a novel idea and quite a rewarding project if you planned it in advance. You could certainly say "not many have got one of these!" It would probably be quite mesmerizing to watch too.

My only argument against it being the "best" would be the time and effort involved into making one materialise, and possibly ironing out any niggles from our own homemade components in service! For a quick, remedial bought solution, the D.I.Y bandsaw certainly fills the brief. It does have one plus over the bandsaw, and that is size. So if that's a big problem for you, then maybe a project would be a better option for a bespoke solution.

I have considered anglegrinders as well and my main objection to them would be the flurry of dust and noise the abrasive action would make, cutting with the bandsaw on the other hand, although creating swarf, is much more manageable because it cuts at a relatively low speed, just like the auto hacksaw,

interestingly, the chopsaw suffers from the same downsides as the grinders, lots of noise and mess, I have had to clear heaps of aluminium swarf away from a little "cutting booth" created in a workshop I worked at simply because the chop saw so messy, you would end up with a metallic spray all over your overalls. However, it does cut far quicker than the bandsaw, however we are not time constrained on this end of the market, and perhaps care a little more about our interior spaces.

Michael W

 

Edited By Michael-w on 02/01/2017 18:21:50

Edited By Michael-w on 02/01/2017 18:23:32

[Ian S CParticipant @iansc]

I helped build over 60 of these machines for feeding out hay from large square bales. All the steel was cut using a 4 1/2, horizontal/vertical band saw. A lot of other jobs too.

The mud guards and chain covers required bits cut off them, an angle grinder with a thin disc was used for this.

Ian S C

[Author]

Posts