Cutting dual wall metal cabinet

[risc]

I need to cut some holes in a metal cabinet, it's a 14Ga, steel, dual wall flammables storage cabinet. The holes will be ~19" x 12", and a couple 4"x4" holes. The dual wall makes it kind of difficult to use a sawzall or jigsaw. I don't need high precision +1/4" -0 would be fine.

I did one and ended up using an angle grinder with a thin cut disc; that was loud, messy and fairly unpleasant, especially cutting the inside wall. I have to do 3 more and I'm not looking forward to it. Is a plasma cutter the way to go? Rent or buy a cheap one? Or, is there a better tool for the job?

 

[rlitman]

For 14 gauge, a pneumatic mini reciprocating saw would be perfect:
http://www.harborfreight.com/high-speed-metal-saw-91753.html

I'd use a blade short enough that you cut the two halves separately. Drill the corners so your inner wall and outer wall cuts line up.

 

[yhprum]

Maybe an air nibbler? Cut the hole on each side of the double wall.
Here is one type, http://www.harborfreight.com/16-gauge-air-nibbler-96661.html

 

[rlitman]

Maybe an air nibbler? Cut the hole on each side of the double wall.
Here is one type, http://www.harborfreight.com/16-gauge-air-nibbler-96661.html

That's a 16 gauge tool, but if you have a 14 gauge nibbler, it's a good idea. You'll get miles more cuts out of a nibbler than a saw blade, though I dislike the pile of razor sharp crescents that always get tracked by my shoe soles everywhere.

 

[risc]

Nibbler is a good idea, it might actually be 16GA I'll have to double check or find a 14GA tool. The blade problem is that there's only about 1/2" gap between the wall, I'd have to cut a blade down unless they make them that small.

 

[csp]

Pretty sure that my little air reciprocating saw has a stroke that's longer than 1/2".

 

[risc]

Pretty sure that my little air reciprocating saw has a stroke that's longer than 1/2".

Yeah, that was part of the problem with the electrical saws. The cabinet is 16GA so I think the nibbler is the way to go.