Evolution RAGE4 metal-cutting saw

[BTL-A4]

I need a metal-cutting saw. I have a 14" Dewalt abrasive saw that is way too big for what I typically do. I also have a really small Harbor Freight abrasive saw that is too small. I want to sell both of these and get something in the middle. Not many choices, though. I found the Evolution RAGE4 that will suit my needs. Anybody have one or use one? I'll be mostly cutting 16 Ga steel (1/8" wall max), max size about 2" square tubes. Might cut some 1/4" bar as well.

 

[rancherbill]

Look at Diablo blades. Diablo makes great blades, and they fit everything from circ saws to cut off saws. Ive seen some of their vids and they look pretty good. They are reasonable priced.

https://www.diablotools.com/explore/circular-saw-blades/?filters=tools:Low%20RPM%20Metal%20Saw

 

[GeoBruin]

The Evo saws are great but I would pony up for the bigger blade. Will a 7-1/4" blade even cut 2x2 tubing at 45 degrees?

 

[Aaron_W]

I have their 7-1/4" multi-material circular saw. I'm happy with it, as a circular saw it is a good quality saw. What really sets it apart from other circular saws if it turns slower extending the life of metal cutting blades.

Based on that if I needed a chop saw, the Evolution would be on my short list.

 

[tarbellb]

Agree w @GeoBruin, footprint and weight don't differ that much to warrant the smaller blade, grab the 14"

Evo does make a good saw , just be sure to get the cast base metal only version

 

[Steve_P]

I have the Morse metal cutting saw, which has a cast base; I spent the extra $ over the Evo because there were so many bad reviews on the Evo because of the stamped base- at that time there wasn't an Evo with the cast base. I'll also say to get something with a cast base because if the tubing moves when you're cutting it, because the base isn't flat, you can ruin the blade- which will get to be very expensive in dollars per cut. Also, IIRC some Evo saws used a proprietary blade, or at least very uncommon blade as far as hole diameter. I wanted a cast base and a commonly sourced blade.

 

[darkzero]

Don't know which model it is but at work we have an Evolution metal cutting saw along side a Dewalt chops saw with an abrasive disc.

The Evolution is no surprise much better to use. Does a great job if you know how to use it & leaves a nicer finish (if that matters). I won't even touch the Dewalt anymore.

But in general I'm just not a fan of them. Especially for my home use, way too noisy & messy. I prefer to use the vertical bandsaw at work when possible & at home I use a H/V bandsaw.

But the Evolution is much cheaper & takes up less floor/storage space. I'm short on space but I still dedicated room for a 7x12 bandsaw (had a 4x6 previously).

 

[BTL-A4]

Look at Diablo blades. Diablo makes great blades, and they fit everything from circ saws to cut off saws. Ive seen some of their vids and they look pretty good. They are reasonable priced.

https://www.diablotools.com/explore/circular-saw-blades/?filters=tools:Low%20RPM%20Metal%20Saw

And available at Home Depot!

 

[BTL-A4]

The Evo saws are great but I would pony up for the bigger blade. Will a 7-1/4" blade even cut 2x2 tubing at 45 degrees?

I looked at a 7-1/4" saw at Home Depot and it appears it will cut a 2" by 2" piece at 45º. However, the Evolution website states that this will cut a 1-3/4" x 1-3/4" piece.

 

[BTL-A4]

I have the Morse metal cutting saw, which has a cast base; I spent the extra $ over the Evo because there were so many bad reviews on the Evo because of the stamped base- at that time there wasn't an Evo with the cast base. I'll also say to get something with a cast base because if the tubing moves when you're cutting it, because the base isn't flat, you can ruin the blade- which will get to be very expensive in dollars per cut. Also, IIRC some Evo saws used a proprietary blade, or at least very uncommon blade as far as hole diameter. I wanted a cast base and a commonly sourced blade.

The RAGE4 has a 20mm arbor. The Diablo blades have a 5/8" arbor. Evolution blades are available for about $30.

How bad is a stamped base vs a cast one? What if I mount this to a board then mount that to a miter saw stand?

 

[BTL-A4]

Don't know which model it is but at work we have an Evolution metal cutting saw along side a Dewalt chops saw with an abrasive disc.

The Evolution is no surprise much better to use. Does a great job if you know how to use it & leaves a nicer finish (if that matters). I won't even touch the Dewalt anymore.

But in general I'm just not a fan of them. Especially for my home use, way too noisy & messy. I prefer to use the vertical bandsaw at work when possible & at home I use a H/V bandsaw.

But the Evolution is much cheaper & takes up less floor/storage space. I'm short on space but I still dedicated room for a 7x12 bandsaw (had a 4x6 previously).

So the Evo is really noisy, huh? Is it as bad as an abrasive chop saw that throws sparks everywhere and makes a huge mess?

 

[darkzero]

So the Evo is really noisy, huh? Is it as bad as an abrasive chop saw that throws sparks everywhere and makes a huge mess?

Oh yes, it's loud. In a shop the noise may not matter but in a home shop & a secret one that I don't want my neighbors to know about, it's unacceptablely loud. I can use my bandsaw late at night if I needed to. A chop saw, I wouldn't use at home if there was no day light.

It's as loud as an abrasive chop saw. It won't throw as much sparks as one but it does still make a mess. That can be manageable though if the noise is not an issue for you.

For a quiet saw, perhaps you are thinking of a cold saw? The slow speed kind with flood coolant. But those things are not considered very affordable.

 

[Aaron_W]

The RAGE4 has a 20mm arbor. The Diablo blades have a 5/8" arbor. Evolution blades are available for about $30.

How bad is a stamped base vs a cast one? What if I mount this to a board then mount that to a miter saw stand?

I'm not sure about the chop saw, but the circular saw I have comes with 2 arbors, a 5/8" arbor for using standard 7-1/4" blades and a 20mm arbor for using with the Evolution proprietary 7-1/4" blades.

I have a Ryobi 7-1/4" miter saw that I have used with a Diablo non-ferrous blade. It makes nice cuts, but it screams cutting aluminum or brass so I rarely use it, instead using the slower, but much quieter 4x6" bandsaw. I don't know how the Evolution will be noise wise, but they do turn slower, so maybe not as horrible a sound. The circular saw turns at 3700rpm vs more than 5300 for most woodworking circular saws. I imagine similar with the chop saw vs a miter saw.

 

[GeoBruin]

The Evo saws are loud. Real loud.

 

[tarbellb]

Super loud and throw hot chips everywhere including your face

Great for fast repeatable cuts

But I've run both 14" dry cut saws and bench top band saws, the band saw is my go to nowadays

Look at bench top swivel head band saws ie FEMI / Klutch / etc... this may be a better option

 

[Beerhippie]

The RAGE4 has a 20mm arbor. The Diablo blades have a 5/8" arbor. Evolution blades are available for about $30.

How bad is a stamped base vs a cast one? What if I mount this to a board then mount that to a miter saw stand?

Totally different animals. The Evo is a low-speed saw meant for use with carbide-tooth metal cutting blades. The Diablo blade is an abrasive blade made for standard cut-off saws.

 

[Beerhippie]

The Evo saws are loud. Real loud.

I wouldn't call my 14" abrasive saw "restful to the ears". It also makes a hell of a mess of fine grindings, has the potential to start fires if you're not careful and leaves a cut that needs a fair amount of cleaning/tuning before welding.

I don't do enough metal work anymore to justify one of the low-speed carbide saws, but I've used one and would buy one in heartbeat if I could justify it.

 

[GeoBruin]

I wouldn't call my 14" abrasive saw "restful to the ears". It also makes a hell of a mess of fine grindings, has the potential to start fires if you're not careful and leaves a cut that needs a fair amount of cleaning/tuning before welding.

I don't do enough metal work anymore to justify one of the low-speed carbide saws, but I've used one and would buy one in heartbeat if I could justify it.

Agree on all counts. But I'm not comparing to an abrasive saw. I wouldn't recommend anyone buy an abrasive saw today. I'm comparing to a bandsaw.

 

[rancherbill]

The RAGE4 has a 20mm arbor. The Diablo blades have a 5/8" arbor. Evolution blades are available for about $30.

You really have to poke around on the website. They make them with 20 holes.

https://www.diablotools.com/products/D0770FM

 

[MongoTA]

I have the Evo 14", low speed, got it WAY back when, it has the stamped steel base and does not have the quick adjust clamp.

Even with those shortcomings over the saws that they offer now ?

I use it in my basement shop, the noise does not bother those upstairs. Not sure if it's the faster motors that are noisier, but this one? It's noisy, but not awful.

The stamped steel base, without a doubt the heavier cast base would be better. But I use it and as a fairly heavy user of the saw in a home shop I have no problems. I always thought I'd make a better base for it, but just haven't felt it enough of an inconvenience to do so. I have this metal saw on a rolling cart. I roll it next to a work table and use the work table as an extension to support when cutting long lengths of angle or tube, it limits torquing the base. I haven't had any problems with misaligned cuts. Don't have many photos of any work, here are some shots of mitered angle, my daughter buit an "industrial vibe" desk and these were the face frames for the drawer fronts.

I recommend "hell no" to an abrasive saw. And heck no to a carbide cutting saw with a fast motor. If you can swing the slower ~1450RPM, I saw go for it.

 

[Beerhippie]

Agree on all counts. But I'm not comparing to an abrasive saw. I wouldn't recommend anyone buy an abrasive saw today. I'm comparing to a bandsaw.

I was also responding to a couple of other posts above that referred to the noise and mess of a carbide saw.

I wish I had a proper bandsaw to compare to--all I have is a Portaband. I occasionally clamp it up in a vise for a vertical saw.

 

[GeoBruin]

I guess what a proper bandsaw is depends on your definition but if you're referring to a bigger saw with an AC motor and a belt drive, they're nearly silent. In my case my horizontal band saw is a DC Direct Drive model and it's nearly as loud as my portaband. I filmed a little video to show you the difference between the two DC saws and my AC vertical bandsaw. Note there's a vibration coming from my vertical bandsaw that has to do with the motor mount hitting the housing. It's not coming from the drivetrain.

 

[finn]

I wouldn't call my 14" abrasive saw "restful to the ears". It also makes a hell of a mess of fine grindings, has the potential to start fires if you're not careful and leaves a cut that needs a fair amount of cleaning/tuning before welding.

I don't do enough metal work anymore to justify one of the low-speed carbide saws, but I've used one and would buy one in heartbeat if I could justify it.

Same here. My abrasive saw hasn’t been used in several years. It’s not there unused for any conscious reason, but I automatically walk over to the bandsaw for cutting metal.

I suspect the mere thought of the sparks, noise, and abrasive swarf does it.

I’ve looked at the Evolution, but haven’t found a good reason to buy one given that the band saw works fine.

A cold cut, low speed saw is tempting, but most I have stumbled on are three phase, and I can’t seeing going down that rathole for the limited use it would see.

 

[BTL-A4]

Oh yes, it's loud. In a shop the noise may not matter but in a home shop & a secret one that I don't want my neighbors to know about, it's unacceptablely loud. I can use my bandsaw late at night if I needed to. A chop saw, I wouldn't use at home if there was no day light.

It's as loud as an abrasive chop saw. It won't throw as much sparks as one but it does still make a mess. That can be manageable though if the noise is not an issue for you.

For a quiet saw, perhaps you are thinking of a cold saw? The slow speed kind with flood coolant. But those things are not considered very affordable.

They are all loud, I guess! Ha! The abrasive saws throw sparks and grinding dust everywhere, the slower Evo-style ones throw chips. Both are loud. Noise is not a major issue, but the sparks are. I do woodworking and metal-working in the same garage, I keep it clean, but there's still sawdust

A cold saw would be much quieter, but those are really expensive, even used.

After reading all these posts and thinking some more, I'm leaning toward a benchtop horizontal bandsaw (something portable mounted in one of those HF mounts). I need to make sure it will cut a 2" x 2" piece at 45º. The HF ones will, barely. The bandsaw will not throw sparks. It makes dust, but it's just around the machine. It's loud, but not nearly as loud as an abrasive chop saw of metal cutting saw.

 

[BTL-A4]

Super loud and throw hot chips everywhere including your face

Great for fast repeatable cuts

But I've run both 14" dry cut saws and bench top band saws, the band saw is my go to nowadays

Look at bench top swivel head band saws ie FEMI / Klutch / etc... this may be a better option

Are you referring to the portable bandsaws mounted in one of those universal horizontal mounts?

 

[BTL-A4]

Totally different animals. The Evo is a low-speed saw meant for use with carbide-tooth metal cutting blades. The Diablo blade is an abrasive blade made for standard cut-off saws.

It's meant for it, but could you still use the Diablo in an Evo saw? There's a max RPM, but not a minimum, or the minimum is within the slower saw's limits.

 

[BTL-A4]

You really have to poke around on the website. They make them with 20 holes.

https://www.diablotools.com/products/D0770FM

I figured I could buy it online, but I like to see what's easily available at the big box stores. Thanks for the link!

 

[BTL-A4]

Thanks to all for your replies and feedback, it's much appreciated. I saw an Evo R355CPS 14" saw on FB for $250 ($349 new). This seems a bit high given that I can buy a EVOSAW380 for $300.

I'm going to look at portable bandsaws mounted in the horizontal cradle and see if that will work. I have a portable bandsaw in a Swag Off-road table that works well enough for most tasks, but the ends need sanding flat.

Could I tune a horizontal one to cut really well, or is it the same as the one I have?

 

[BTL-A4]

Anyone use or have any experience with this one? Is the company reputable? The reviews were decent, but there weren't a lot of them.

 

[dnschmidt]

This little dry cut saw has been out for at least 10-15 years. Sawblade.com has been selling a model of the same size forever: https://sawblade.com/order-circular-saws.cfm
A friend of mine build an entire dune buggy using this little guy and it got the job done. Do I like it as much as my Porter-Cable 1410? NO but it does work.

 

[tarbellb]

Are you referring to the portable bandsaws mounted in one of those universal horizontal mounts?

Nope

rotating saw head w static vise, so much better for keeping things easy

like this

https://www.northerntool.com/products/klutch-benchtop-metal-cutting-band-saw-5in-x-4-7-8in-400-watts-110-120v-101670

or the FEMI version

 

[BTL-A4]

Nope

rotating saw head w static vise, so much better for keeping things easy

like this

https://www.northerntool.com/products/klutch-benchtop-metal-cutting-band-saw-5in-x-4-7-8in-400-watts-110-120v-101670

or the FEMI version

Thanks for the clarification! This is a pricier version of the one I have a photo in above. I'm leaning toward getting that one. I'm hoping to hear from anyone who has one, or at least has experience with Northern Tool and/or Klutch.

 

[GeoBruin]

Thanks for the clarification! This is a pricier version of the one I have a photo in above. I'm leaning toward getting that one. I'm hoping to hear from anyone who has one, or at least has experience with Northern Tool and/or Klutch.

I hate to tell you but that really doesn't look like a great saw. It doesn't appear to have a true mitering function. If you're dead set on a Klutch, take a look at this model.

https://www.northerntool.com/products/klutch-benchtop-metal-cutting-band-saw-5in-x-4-7-8in-400-watts-110-120v-101670?cm_mmc=Google-pla&utm_source=Google_PLA&utm_medium=Metal%20Fabrication%20%3E%20Band%20Saws%20%2B%20Accessories%20%3E%20Stationary%20Band%20Saws&utm_campaign=Klutch&utm_content=101670&ogmap=SHP%7CPLA%7CGOOG%7CSTND%7Cm%7CSITEWIDE%7COOT%7C%7Bcampaign_name%7D%7C%7Badgroup%7D%7C%7C19587256490%7C148102464129&gad_source=1&gclid=Cj0KCQiApNW6BhD5ARIsACmEbkVj0DAtpWd9nVXEeZWlDfPcMCLeV31rvl0UFXi1Xp7hCNFdri9pCTEaAv0WEALw_wcB&gclsrc=aw.ds

 

[tarbellb]

Agreed go with a dedicated bench top not a handheld put into a contraption.

The entry point on these isn't much higher then what you are comp pricing


This would be the equivalent of putting a 71/4" circ saw into a pivoting vise

 

[BTL-A4]

I hate to tell you but that really doesn't look like a great saw. It doesn't appear to have a true mitering function. If you're dead set on a Klutch, take a look at this model.

https://www.northerntool.com/products/klutch-benchtop-metal-cutting-band-saw-5in-x-4-7-8in-400-watts-110-120v-101670?cm_mmc=Google-pla&utm_source=Google_PLA&utm_medium=Metal%20Fabrication%20%3E%20Band%20Saws%20%2B%20Accessories%20%3E%20Stationary%20Band%20Saws&utm_campaign=Klutch&utm_content=101670&ogmap=SHP%7CPLA%7CGOOG%7CSTND%7Cm%7CSITEWIDE%7COOT%7C%7Bcampaign_name%7D%7C%7Badgroup%7D%7C%7C19587256490%7C148102464129&gad_source=1&gclid=Cj0KCQiApNW6BhD5ARIsACmEbkVj0DAtpWd9nVXEeZWlDfPcMCLeV31rvl0UFXi1Xp7hCNFdri9pCTEaAv0WEALw_wcB&gclsrc=aw.ds

Thanks. I'm not dead set on a Klutch per se, I just don't see paying hundreds more for what looks like a similar saw. A guy did a review on the one you linked (which has lots of clones also) and he liked it.

I need something smaller, both for storage and cutting (2" square is about the biggest I'll cut). I'll take a 2nd look at the one you linked; might be a better choice, even though it's twice as much. As @tarbellb pointed out, it's not much more than the other saws I was looking at.

 

[tarbellb]

There's also a brand called Trajan that looks interesting. No personal exp, another player in the mid tier import field

 

[GeoBruin]

There's also a brand called Trajan that looks interesting. No personal exp, another player in the mid tier import field

I really like the look of the Trajan saws. I finally got a chance to check one out in person recently and I was impressed. There are also several advantages over the other saws in this size category including a cast base, more powerful motor, larger cit capacity, and a true variable speed motor. That said, it's about double the cost of the Klutch.

 

[Aaron_W]

If your are now considering other saws, band saw is really nice. I bought the Evolution circular saw for cutting stuff too big for the bandsaw, mostly sheet or plate, but the bandsaws get most of the work. I just got a small metal cutting vertical bandsaw so the Evolution saw may just keep getting used as a tracksaw on my wood working projects which is already where it gets used the most.

For a small bandsaw I would love to have something like this Grizzly. Not much larger than the 4x6" horizontal, but I used an Ellis mitering bandsaw in welding class, and having the head swivel instead of having to move the stock when cutting at an angle is so much nicer. With a conventional horizontal, you either need a ton of space if dealing with long stock, or turn the whole saw, neither of which is convenient in a small shop.

Grizzly G9742

But wow has the price gone up on these, seems like just a year or two ago they were around $500.



I have 2 horizontal bandsaws, a HF 4x6" which has more than paid for itself at the $200 I paid for it, even at the $350 they cost now a decent deal.

Later I added a 50 year old 6x9" Kalamazoo that runs circles around the HF, but is also twice the size. I'd love to have an Ellis mitering bandsaw, but at $3000+ I don't see that happening unless I find a great deal on the used market.

Don't overlook power hacksaws. Yeah, the little 4x4" Covel / Atlas / Craftsman are slow, and I think the experience that turns many off of hacksaws. Those were budget saws made for homeowners cutting little stuff. Any of the smaller 6x6"-8x8" -ish commercial saws from Keller, Peerless, Racine, Marvel etc are decent saws, and they compare well with similar cabacity bandsaws. You can often get hacksaws at a decent price since so many people dismiss them as obsolete, and for a similar capacity they are only about 2/3 the size of a bandsaw.

Even the little homeowner saws like the Craftsman, Keller Jefferson etc work, you just need to be patient and in their favor they are very compact. They also will happily chug along cutting while you do other things.
My little Covel is considerably smaller than my HF 4x6", and my Keller 7x7" not much bigger than the HF saw.

Yeah, I may have a saw fetish.

 

[larry4406]

I really like the look of the Trajan saws. I finally got a chance to check one out in person recently and I was impressed. There are also several advantages over the other saws in this size category including a cast base, more powerful motor, larger cit capacity, and a true variable speed motor. That said, it's about double the cost of the Klutch.

The Trajan looks pretty decent. Says aluminum base vs the stamped steel the others have.

Trajan 125 Portable Band Saw

Cut all types of steel up 5” | Make all the cuts you need | Powerful 1.35 hp 1010W motor | 98-262 ft/min speed | M42 bi-metal blade included | 100% satisfaction guarantee

trajan125.com

Even the Femi has a stamped steel base

782XL Mitering Bandsaw, HEM Saw, Femi

The HEM Saw 782XL portable bandsaw is a great fit for hobbyists and those needing a accurate portable saw with a large cutting capacity.

www.trick-tools.com

 

[BTL-A4]

I chatted with the Klutch folks. The smaller saw will only cut a 1-1/8" x 1-9/16" piece at 45º. The bigger saw will work, but it's a bigger saw and will not fit well, if at all, where I need to store it.

After rethinking all this, I realized I do have a portable bandsaw on a Swag Offroad table that might work. I'll have to try it and see if it will serve my needs. I don't cut tons of pieces on a regular basis, so it might be sufficient. I use it all the time for rough-cutting metal to size before I mill it or turn it. I'll have to see how well it will cut miters.