sheet metal cutting odd shapes

[scale]

I am trying to zip out some rusted holes in my pickup bed.

I have been using a 4in angle grinder for the larger straightish sections but i have some contours around the fender wells and such that it is too big for. I also have some tight radius turns to cut.

THe 4 1/2 angle grinder is too big. The tiny dremel cutoff wheels are useless

I have been using a hacksaw blade and thick gloves but it is really really slow going.

Is a jigsaw the best answer here with a a metal blade? Thats about the only tool i am familar with that will cut odd shapes. I might have to go get myself one but i want to avoid spending the $75 (to add to my ryobi 18v tools).

 

[kbeefy]

how about a nibbler attachment for your cordless drill?

Amazon Link

 

[kbeefy]

This is the one I have, but I haven't used it much....

https://www.baddogtools.com/product/z-bad-dog-biter/

 

[scale]

wow...that is really neat. I bet that is handy as heck when you need it.

 

[harley jim]

I was going to suggest an air saw but after seeing kbeefy's nibbler I may not suggest one.
That's is nice, I have been looking at there cut off blade for a 4" angle grinder.

Sent from my SM-A102U using The Garage Journal mobile app

 

[Gotcha640]

Die grinder? How big are you talking? How do you plan to cut the patches? If flat, maybe you could put the carbide bit in a router, easier to hold on to.

 

[scale]

the patches will be just 14ga sheet metal dropped over the hole and welded on. Nothing fancy. Its got 200k miles so its about had it. I just want to patch the holes now that i have the bed off the truck.

They are all kinds of odd shapes from the bed up the sides of the wheel wells and places like that.

 

[Stephenw]

Air body saw or air die grinder with a cutoff disk.

 

[scale]

Air body saw or air die grinder with a cutoff disk.

Isnt a air die grinder with a cutoff disk ...just a 3 inch disk? I dont know that would much different than a angle grinder.....besides air.

 

[Stephenw]

Isnt a air die grinder with a cutoff disk ...just a 3 inch disk? I dont know that would much different than a angle grinder.....besides air.

They are 3" when new. They get smaller in diameter with use. I save the worn down ones to use in tight spots. Overall, an air angle die grinder is much more compact than a 4 1/2" electric grinder.

 

[Stephenw]

Size comparison...

 

[scale]

ah..thanks for the comparison photo......nice Metabo. I have the same.

 

[dnschmidt]

Plasma cutter.

 

[MJK]

Kett 440s are quite useful and often available cheaply on eBay. I love mine for sheet metal.

 

[GeoBruin]

A jigsaw with a metal cutting blade is such a sweet way to cut sheet metal. I have a nibbler attachment for a drill and it's okay but doesn't seem as controllable and it leaves tiny little razor sharp "nibbles" everywhere.

Plus, when you're done, you have a jigsaw which is a way more versatile tool than a nibbler or electric shears.

 

[whateg01]

I have this and have used it for aluminum and some thinner steel. I'm not sure how well it would work on 14, but it's cheap.

https://www.harborfreight.com/16-gauge-air-nibbler-96661.html

Dave

 

[HMCFab9]

pneumatic cutoff tool with the 3" cutoff wheels.

That's what 99% of bodyshops use & I use one every day.

 

[ez-duzit]

You want something like this:

 

[manwithtools]

Die grinder? How big are you talking? How do you plan to cut the patches? If flat, maybe you could put the carbide bit in a router, easier to hold on to.

Be sure to have the medics on speed dial when you try the carbide bit in a router suggestion....

 

[Jazz1]

They are 3" when new. They get smaller in diameter with use. I save the worn down ones to use in tight spots. Overall, an air angle die grinder is much more compact than a 4 1/2" electric grinder.

I as well save small die grinder wheels for tight cuts etc. I have small air saw but rarely use, it’s awkward

 

[eyeball]

Air body saw or air die grinder with a cutoff disk.

Air saw has my vote... mine came in real handy when restoring an 1970 Nova that was full of rust. The blades are narrow and the body (unlike a jigsaw) is very compact and thin letting you get into tight spots and right up against any obstruction.

My Aircat 6350 air saw was one of the few air tools I kept when switching over to battery powered tools.

If you are interested here is a link: https://www.amazon.com/dp/B01C8YOHEK/?tag=atomicindus08-20