Affordable, Accurate method to cut steel?

[Chuck79]

I use a dewalt chop saw and 4.5 angle grinder with HF cut-off wheels. Works for me just fine.

http://www.factoryauthorizedoutlet....aw-w-quick-change-keyless-blade-change-system

http://www.factoryauthorizedoutlet.com/dewalt-dwe4011-4-5-small-angle-grinder

 

[1949 caddyman]

I have been using a home depot metal abrasive blade in my craftsman chop saw for 20 years, it still cuts wood & metal fine. I have probably used up 10 blades in that time. May be better ways to do it , but this works for me.

 

[bullnerd]

Same here, old Makita, all metal 10", chop saw with an abrasive blade, $40 at a yard sale, 20plus years of use.

 

[PCustoms]

OP needs to define the 'needs' better.

"accurate" as in to within 1", or accurate as in within 1/8", or accurate as in within 0.005" of the desired dimension.

"affordable" as in a hacksaw (~$10), or a grinder and cut-off wheel or recip-saw with blades or jigsaw with blades (~$100, to nearest order of magnitude, with some 'consumables'), or up from there.

Also, has to define what he wants/needs to cut. Material, thickness of material, type of cut(s) and whether just straight cuts or curved cuts or a combination.

And also, some cutting methods are just 'easier' than others.

You can cut things with many different tools. So, buy them all. CNC plasma table FTW.

(but don't use a plastic-part wood-cutting power-miter-saw with an abrasive cut-off disk on metal or use (most any) of those saws with a carbide-tipped steel cutting blade. IMNSHO. Those are the 'wrong' tool for the job. Yes they make carbide-tipped circular saw blades that can cut (and do quite well within the tool and blade limits steel, but RTFM on the specific blade first.

It's actually (to me anyway ) kind of unbelievable at first how well a blade (from Freud http://www.diablotools.com/products/product/D0748F or Lenox http://www.lenoxtools.com/Pages/Product.aspx?productId=MetalCuttingCircularSawBlades or Morse, etc , etc) can cut through steel with a 'standard' 5000 rpm handheld circular saw (aka 'Skilsaw'). Straight cut is not quite like cutting through butter, but still quite amazing just slicing through steel with a circ-saw. Hot sharp chips, loud (but still quieter than an abrasive cutter), and a sharp edge on the cut line.

But for general over-all speed and ease, plasma is quite amazing too.

Maximum planned material at the moment is 3/16 wall 2x4 steel, would like to cut that to within 1/32". Flat stock will be limited to 3/16 plate, and I would like to keep that to 1/16" with a clean edge. Typically I deal with machined parts in the +/- 0.0005" range all day, if not smaller. If I need something more precise, I'll cart it into work and spend some time on the mills at lunch.

Currently I own a small grinder and assorted wheels. I know what I can do with it, but i always despise cutting.

Long term plan would be a horizontal bandsaw for the tubing and send the flat stock out for waterjet or CNC plasma. Just looking for a way to get by until my expendable cash builds up.

Wouldn't dream of destroying a nice plastic miter saw with an abrasive blade. Was thinking an older all metal version, or a cheapo model with the carbide tipped ferrous metal blades may work (if the RPM matches of course). That Freud blade has a max RPM of 5800, which coincidentally is the max developed speed of a 7 1/4" circular saw.

 

[sberry]

What are you building that requires such tolerance and if that was the case it is worth some investment vs some cobble job.

 

[Tucko]

Way ahead of you there, wouldn't ever think of buying anything like that from HF.

Very true, My cheapo ex boss bought HF blades. I tore him a new one when they developed cracks in the blade upon first use.....

 

[brucer]

First the Horizontal Saw will burn up the motor, then after you replace the roller bearings will start to cut straight, and almost immediately you realize not to buy blades from Happy Fart

Get a good 14" Chop Saw off CL or bite the bullet and buy 1 new

Well this is pretty much bs..

I've owned my HF 4x6 horizontal band saw for 15yrs. I've adjusted bearings once (the day I brought it home), changed the oil in it once (the day I brought it home).. other than that I have tightened the belt a few times and put quality Olson bi-metal blades on it its entire life.. I couldnt tell you how many tons of steel has been through that little 4x6 saw.. Worth every penny of the $150 I give for it.

plus I dont have the slag allover my shop, and my shop dont smell like a pile of burnt socks when I use it.... I would use my cnc plasma table all day in my shop before I would make a single cut with an abrasive saw inside my shop...

The 4x6 horizontal saws are about the best deal going from HF.

 

[ng8264723]

A nice old power hacksaw. It will cut anything. Cut it square and tru and quietly as well!

 

[buening]

Well this is pretty much bs..

I've owned my HF 4x6 horizontal band saw for 15yrs.

Believe it or not, quality on the HF horizontal band saws has gone down compared to 15yrs ago. Its still a good buy IMO

 

[Kevin54]

I'd never run an abrasive blade in a circular saw. Look on CL and see if you can't pick up a cheap O/A setup, a horizontal bandsaw, or invest in something like a Grizzly or JET metal cutting bandsaw. Or yet again, you can get the handheld portable bandsaws, although I'm not sure of the proper name other that portable bandsaw.

 

[ng8264723]

As I said why not a neat old power hacksaw?

The above saw is the model I have. I bought it for $100! It will cut anything. It is so much fun to watch!

 

[tarbellb]

Heres a quick run down for what/size/cost for a homeowner to light fab shop uses:

bar, tube, angle up to _~3 (limited) = Portaband saw = $250 = fairly accurate
____________________~3" = 8" Cold cut saw = >$1000 = most accurate
____________________~5" = 14" Abrasive saw = $75-150 = fairly accurate
____________________~5" = 14" Dry cut saw = ~$300-500 = very accurate
____________________~10" = Horizontal band saw = ~$200-2500 = very accurate

sheet, plate ___~3/4" thick = 8" Metal circular saw = $250-350 = very accurate
______________1/4" - 1"+ thick = Plasma = $500-2500 = very accurate
______________1/2" thick(?) = 4.5" angle grinder = $50-150 = not accurate
______________1"+ thick = Ace torch = $300-500 = fairly accurate

This is my opinion, but based off working with most these tools. All have their PROS and CONS, including price, accuracy, range of cuts, durability, etc....

Did I miss any common tools?

 

[Jere]

Way ahead of you there, wouldn't ever think of buying anything like that from HF.

HF actually sells really nice USA made bi metal blades called super blade or something like that. Just make sure you read the package, they are mixed in with the junk import blades.

 

[KerryH]

My HF bandsaw is my go to tool for cutting. Easily one of the best tools I've ever purchased. My shop isn't very large so I love the fact that it's quiet and it doesn't shoot metal dust everywhere like an abrasive saw does. Just spend a little time getting it dialed in and it cuts extremely well with a quality blade.

 

[pepi]

First the Horizontal Saw will burn up the motor, then after you replace the roller bearings will start to cut straight, and almost immediately you realize not to buy blades from Happy Fart

Get a good 14" Chop Saw off CL or bite the bullet and buy 1 new

Are your eyes brown ?

 

[brucer]

Are your eyes brown ?

 

[ng8264723]

I don't get it

 

[brucer]

I don't get it

I was thinking full of $hit?

 

[DpSyChO]

Another vote for a HF bandsaw.
I got a HF 4x6 bandsaw around 10 years ago. I was squaring up a pc of tube that had been cut out of square with a porta band. I set up the cut, and went in the house to get something to eat. The cut off pc got wedged between the blade and guide and stopped the blade, motor was shot by the time I came out and checked on it. Replaced motor with one I took off something at the scrap metal yard, been chugging right along since. My motor problem I feel was my fault.

 

[R.Anderson]

HF is what I use the most with some tweaking you can have it cut to 1/32" easy just get your self a Bi-metal blade for it the ones HF sell here are USA made and hold up. Then plasma for sheet and plate or anything that won't fit in the band saw, and for harden steel chopsaw. Like some one said on hear there are many ways of cutting. I have a good size arsenal for cutting metal HF band saw, Dewalt portable band saw, Porter Cable sawzall, chopsaw, jigsaws, plasma cutters, and hacksaws.

 

[R.Anderson]

HF actually sells really nice USA made bi metal blades called super blade or something like that. Just make sure you read the package, they are mixed in with the junk import blades.

Second the Super Cut and second the "read the package" make sure its the Bi-metal blade.

http://www.harborfreight.com/64-1-2...nch-bimetal-supercut-bandsaw-blade-97119.html

 

[cousin eddie]

i too, am curious why theres not much mention of a power hacksaw, even a homemade one. there was a post of a hf portaband turned into a chop saw style saw, im thinking of building one of those too.

 

[Jack Burton]

I loathe Harbor Freight but I always rave about the same two things, their US General toolboxes and their 4x6 horiz. bandsaw. I got my bandsaw for around $160 w/ coupon a couple years ago. They kick ***.

 

[muibubbles]

Any thoughts on the Evolution saws?
http://www.sears.com/shc/s/p_10153_12605_00961252000P

http://www.sears.com/evolution-evor...0925864000P?prdNo=10&blockNo=10&blockType=G10

I have the 7" model and it *****. the fence isnt 90* (i believe its a common issue but cant remember if they were sending replacements for these..)

Also it leaves burrs and all my cuts need to be dressed.. not sure if i just got a dud or what, but IMO one of the worst tools I've bought. I wish i ponied up for a larger dewalt or milwakee brand dry cut saw... I still use it however for "rough" cuts since its very inaccurate.

actually ill email evolution to see what they say about the fence..
http://www.homedepot.com/p/Evolutio...i_kw=&ci_gpa=pla&ci_src=17588969#.Uon-AeBpufQ

 

[dadsEH]

Just won a NIB Lincoln MIG on eBay by accident (threw a bid out for the hell of it, it stuck) so figured now is a good time to stop lurking.

I've got some accessories to purchase, so not much $$ available for cutting tools. Has anyone used a 12" woodworking miter saw with an abrasive blade?

Not sure I want to beat up my nice compound setup, but I frequently see used makita's on CL for $50.

As far as 3/16" plate goes, anything better then a grinder, cutoff wheel and patience?

You plan on going commercial?