How to cut this out?

[clarkebd]

Hi All-

Rookie metal person here. I'm trying to fabricate something and I have a
2" x 2" x 1/4" square bar as in the picture and I want to cut out the white square on the top side only (1 1/4" sq).

What's the easiest way to do this?

It's too small to use my angle grinder, and really thick to hacksaw it by hand (drill a hole to get the hacksaw started).

 

[dlewis]

Depends what tools you have at your disposal,hole saw the finish the corners with jigsaw.

 

[rlitman]

Do you have a torch?

 

[clarkebd]

Sorry, forgot to add, no torch handle.

As to a hole saw and then jig saw the corners, where's a reasonable place to get blades? My local Lowes and/or Home Depot seem to be heavy towards wood working (which makes sense).

Is there a good priced place online that's easy to order a bunch of stuff from?
I've been buying drill bits one at a time as I need them, but that gets expensive quick.

 

[BMW Rider]

You could also start with drilling a hole at each corner, then hole saw out the center. That would leave minimal material to remove and would form nice radiused corners if that is desirable.

 

[metaleltr]

Home depot will have metal cutting blades, typically in packages with wood cutting blades.

 

[metaleltr]

You could also cut it out by cutting a series of 1/8" holes along the perimeter, knocking it out with a chisel and finalizing with a file or die grinder.

 

[porschedude996TT]

Drill in each corner to make the inside radius, and then drill holes to almost connect each other. Then file or grind out the points. It would be much easier to drill the four corners and then find someone with a tourch. How long is the tubing? Can you transport it to a muffler shop?

 

[Zeke]

With a square drill bit.

 

[MoonRise]

Sharks, with lasers on their heads.

Drill holes (regular twist drill bit) in the corners, then either multiple holes drilled along the sides of the 'hole' and cleaned up with a die grinder and burr/stone or use a jig saw with a metal-cutting blade to connect the corner holes.

Drill holes in the corners and connect with a small cut-off disk (Dremel cut-off disks are about 1" diameter to start with, or a cut-off tool with the 2-3" wheels). Finish off with burr or stones in die grinder (or equiv) or filing.

Find a buddy with a torch or plasma and let them cut it out in about 1 minute.

 

[k-os]

With a square drill bit.

 

[Jim Johnstone]

What sort of radius in the corners? Personally I would mill it or wire edm it but not everyone has access to that sort of equipment.

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[ilovevocs]

If you have minimal tools I agree with the above drill and file option. You may also be able to get your hands on a hacksaw like this to cut between the holes and limit filing for a minimal investment.

http://www.grainger.com/Grainger/ST...1C069&ef_id=Ud2P1wAABTR31j0z:20130711161040:s


If your looking to make a small investment and own a compressor a Die grinder with a roloc / abrasive disk would also be an asset.

Another option if you have access to a arc welder is to crank the amperage up and blow a hole through it.

 

[clarkebd]

Thanks for all the ideas guys. I'll try the drill 4 corners and use a jig saw metal blade to connect them. I want the corners squared as much as possible.

I need to slowly invest in tools and will eventually have what I need to do it quicker/nicer.

 

[readhead]

If I may ask, what is the hole for?

 

[Scrambler82]

Thanks for all the ideas guys. I'll try the drill 4 corners and use a jig saw metal blade to connect them. I want the corners squared as much as possible.

I need to slowly invest in tools and will eventually have what I need to do it quicker/nicer.

As suggest above drill a few extra holes in between the corner holes to relieve the stress on the Jigsaw and the actual time it will take to cut.
Since the wall is ¼” it is thick, use a lot of lubricant and use the extra hole method.

 

[aggierailroad]

Be careful that the stroke on your jigsaw (ba da dum) won't cause the blade to be bouncing off the bottom wall of the tubing. Be prepared to buy a short blade and possibly cut the end off so that it can reciprocate without throwing the saw out of your hands.

 

[Strouty]

Be careful that the stroke on your jigsaw (ba da dum) won't cause the blade to be bouncing off the bottom wall of the tubing. Be prepared to buy a short blade and possibly cut the end off so that it can reciprocate without throwing the saw out of your hands.

Also you could add a spacer under the foot of the jigsaw.

 

[Zick]

I know you probably don't have one (and neither do I) but I'm suprised nobody mentioned using a plasma torch.
Seems this would work really well here if you knew someone that had one.

 

[rsanter]

You only have to drill 2of the corners and the jig saw from those to connect at the other two

Bob

 

[k-os]

What sort of radius in the corners? Personally I would mill it or wire edm it but not everyone has access to that sort of equipment.

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He only wants to cut it on one side. Wire EDM wouldn't get him that.

 

[383 240z]

Where are you located? If you are close to me, I'd say bring it over and I'll chuck it in the mill and run it out for you. Keith

 

[rlitman]

I know you probably don't have one (and neither do I) but I'm suprised nobody mentioned using a plasma torch.
Seems this would work really well here if you knew someone that had one.

I didn't mention it, because I think we can safely assume that if he asked the question, he doesn't have access to one.

 

[clarkebd]

Yep, no plasma. That would be great though.

I did find short 14 tooth jig saw blades and it worked great. I drilled out the corners and then one bigger hold in between each to shorten the distance to cut.

That big piece goes into my trailer hitch. The hole is for a piece I'm sticking straight up (I wanted it recessed down into that bar instead of just welding it on top).

The whole thing when done is for a canoe carrier. Simple project for my 2nd item ever fabricated.

 

[kevin47]

Good Luck, buddy...This is not a typical job attempted in your garage without the proper equipment ( think Bridgeport ) appears to be 1/2 inch material...Depends a lot on how "clean" you need the hole...Don't kid yourself, if you think a hacksaw would in any form or way, would be of any help cutting this hole, forget it...Either, drill a small hole and torch, it using a "guide"...Wear out a few hole saws ( unless to can get a hold of a "hole hog" )...Or drop it off at your local machine shop ( $$ ) and wait up to two weeks...Sorry to be the bringer of bad news, but you asked for it...I used to do these all the time...and here's the kicker...Anyway you do this...It's going to "warp" the tube, slightly...Even being 1/2 inch, you will notice a slight bend, when your done...

 

[larry_g]

Good Luck, buddy...This is not a typical job attempted in your garage without the proper equipment ( think Bridgeport ) appears to be 1/2 inch material...Depends a lot on how "clean" you need the hole...Don't kid yourself, if you think a hacksaw would in any form or way, would be of any help cutting this hole, forget it...Either, drill a small hole and torch, it using a "guide"...Wear out a few hole saws ( unless to can get a hold of a "hole hog" )...Or drop it off at your local machine shop ( $$ ) and wait up to two weeks...Sorry to be the bringer of bad news, but you asked for it...I used to do these all the time...and here's the kicker...Anyway you do this...It's going to "warp" the tube, slightly...Even being 1/2 inch, you will notice a slight bend, when your done...

Did you bother to read the post where he said it's been done with a hack saw? Or even the first post where it says the material is 1/4"?

lg
no neat sig line

 

[Jim Johnstone]

He only wants to cut it on one side. Wire EDM wouldn't get him that.

Yeah I was thinking it was all the way through

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[Kevin54]

Drill a series of holes on all four sides of the square. Then if you have the holes close enough, knock out the plug. After that, use a deburring tool to clean it up.

 

[kazlx]

I did mine with a plasma torch and a carbide burr before I had my mill. You could easily drill the corners and jigsaw. I would shorten the blade instead of using a spacer so you can see what you are doing. Hard to file just one side. Carbide burr is easy and cheap. HF air grinder and a burr. Be careful though...those things throw off the nastiest little slivers.

Like so:

 

[ADSR]

Use a square hole saw.

 

[clarkebd]

Yeah, the hole didn't cut perfect but was close enough that I had to tap the other material down into it. So a nice fit before welding up.

Larry_G you are right, 1/4" material. Hacksawing was taking forever but did work. I was just asking for a faster method and went with the jigsaw as I had it and only had to buy a blade. Worked great. Thanks again everyone.

 

[BFBOB]

With a square drill bit.

Yup. AKA "broach". No prob as long as you've got the machine it hooks up to.

 

[Jim Johnstone]

Yup. AKA "broach". No prob as long as you've got the machine it hooks up to.

That would be one hell of a broach for one hole. Another option would be an old machine shop that has a shaper and have them shape the hole.

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[Kevin54]

I need to make one of those. I was thinking just yesterday about going to Lowes to pick up some lumber for the neighbor woman and thought that it would be great to have an extension for the receiver to be able to haul longer loads.

That is officially on my to-do list.

 

[sberry]

One thing you will learn from this about fabrication,,, here is an easier way, stuck on and welded. Not that it helped but,,, how strong does this need to be?

 

[readhead]

Put on top and weld it. Done.

 

[454ragtop]

That would be one hell of a broach for one hole. Another option would be an old machine shop that has a shaper and have them shape the hole.

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Huh? What kind of shaper is that?

 

[TwoInch]

jig saw for the win!!

i remember reading i think on here, about using a jig saw as the poor mans torch. i thought, man that has gotta be terrible to try a jig saw on 1/4 or 3/8 steel.

then i tried it, and amazing how well a jig saw will slice through steel plate or tube such as this. i suggest all to get decent metal blades for their jigsaws for those smaller jobs where its much more time and money efficient to pull the jig saw as opposed to torch or other tools.an oscillating jigsaw is even better, cuts like butter.

remember to lube well.

 

[Richard D]

Huh? What kind of shaper is that?

Don't see them very much any more.
http://en.wikipedia.org/wiki/Shaper

 

[MarkG]

Put on top and weld it. Done.

It might be an industrial-strength peace pipe and therefore, he needs the hole, but otherwise, I agree completely! (stronger, simpler, faster)