Best method for cutting metal on this project?

[BlackdogGS]

I finally found some rocket stove plans online that I’m happy with. Basically you glue the pattern on your material and cut it out. I have a plasma cutter that would normally make short work of this but the heat would burn the paper. I got these plans from a YouTuber and he shows how he cut them out using a jig saw. The metal is 3/16” and my saw with new blades won’t hardly scratch it. His video shows him buzzing through it like it was wood. I ended up using a cut-off wheel and it took about 3-4 hours and now I have another 3-4 hours of grinding to do. Is there a saw blade that can actually cut 3/16” metal?

 

[BlackdogGS]

Here’s his video:

 

[gearhead1]

Look at an Evolution saw. They have hand held and chop saw versions.

Evolution S185CCSL: Metal Cutting Circular Saw 7-1/4 in. Blade

Features Looking for a heavy-duty circular saw with a powerful 15 amp motor, 11.4 lb light-weight design that cuts steel like a hot knife through butter? The S185CCSL is the ideal metal cutting circular saw with a robust and highly durable design, built for heavy-duty, day in, day out steel...

store.evolutionpowertools.com

Evolution EVOSAW380: Metal Cutting Chop Saw With 14 in. Mild Steel Blade

Features The incredible EVOSAW380 chop saw slices through mild steel with ease. No heat and virtually no sparks, producing a smooth, burr-free, instantly workable finish. Unlike abrasive chop saws, the EVOSAW380 is the cleanest, fastest and most affordable way of cutting steel. Utilizing a...

store.evolutionpowertools.com

 

[tarbellb]

Well his video is sped up, but with the correct speed and blade a jig saw can cut 3/16". ie down stroke cut action with 18-22tpi

Havent listened to or studied the video, but 3/16" wall seems very heavy for this application? Why so heavy of wall?

 

[LXCam]

Well first off that sure looks like .120 wall tubing. But even at that it takes time with a jigsaw. So dont go losing sleep over that vid.

Past that you could always use a straight edge and the plasma for the majority of the cut then use the jigsaw for detail work.

 

[BlackdogGS]

If I could somehow transfer the pattern directly to the metal, maybe one of those etching tools? I was planning on making 2 of these, I have 1 cut out so far and need to finish grinding it. I’m glad I’m not making more then 2.

 

[bsaint]

Where ya at I can laser cut them on our 5 axis Trumpf Cell

 

[cvairwerks]

Dykem and a scribe, then plasma.... Old style layout work.

 

[fordkid88]

Cut off wheel. It's not a machine tolerance project, rip into it and hit it with a flap disc afterwords and call it a day.

 

[BlackdogGS]

I asked the YouTuber guy. This is what he used.
Home Depot Diablo DJT118B

 

[csp]

Mark the steel with a sharpie and then a scratch awl using a steel rule to keep the lines straight. Remove the pattern at that point.

Then cut it with a cut off wheel on an angle grinder on the scribed lines and you should have minimal grinding to clean it up.

Tubing is not difficult to cut cleanly with a cut off wheel.

 

[Merch1]

Waaay back when I was an apprentice, we were shown how to use a centre punch and follow the cut lines. Punch right on the pattern. Remove the paper and cut following the punch marks. The theory being that if you cut half of each punch mark off you would be following the line exactly. Still use this method sometimes.