Metal cutting chop saw

[bluedog225]

Good morning,

I need to make a couple of dozen cuts in 3/8” 4“x4” angle iron. I’d like clean, straight cuts. Light use. No other projects planned.

I see metal cutting chop saws with both abrasive and metal blades.

What brand and type of blade do you guys recommend?

Happy to go with Home Depot or harbor freight if it will get the job done.

Thanks

 

[The Cobbler]

a carbide blade saw will be costly compared to an abrasive cut off wheel
I'd look for a used chop saw and get as thin a wheel as you can ( takes less material)

 

[Mike65]

If you have an angle grinder, get a metal cutting blade & use it. I have done it this way in the past & has worked great. I used a larger blade when I had to cut the bolts for the rear springs on my Mustang when they were seized in the bushings. They come in 4.5 & 6" diameters. I made a shield for my angle grinder to protect my hands when using the larger blade.

 

[The Cobbler]

yes to above poster, you can get decent cuts with above if you are careful

 

[PCustoms]

My experience with abrasive "chop" saws and thick angle has not been good...

It will cut slow and the blade will wander.

For a few dozen cuts grinder or a skillsaw with metal blade get my vote.

 

[jack stand]

If you have a good "skillsaw", a metal cutting blade (carbide) will give you good results if you're experienced enough with the saw.
The difficulty is having both cuts from each face of the angle meeting nicely at the corner.
If the cost of a metal cutting (carbide not abrasive) chop saw is bearable, that will give you the best results quickly.
"A couple of dozen" is not a project that I'd jump into (with 3/8" x 4" angle) with an angle grinder & cut off wheels.

 

[LopezBart]

I use a 4x6 metal cutting bandsaw for cuts like this; the chop saw is slow and hot on thick metal.

 

[jkuro]

A couple of suggestions:
Sawzall with metal cutting blade.
Torch with straight edge.

 

[Lumpy102]

I'd try to find somebody with a stationary band saw, or look up on Craigs list/Facebook marketplace for a used one. You can resell when you're done. I paid $250 Canadian for a decent one a few years back, cuts about 8" x 10". You'll find that it's hard to make a nice cut with an angle grinder or abrasive wheel, lots of sparks, heat, and some smoke. The cold cut chop saws cut better, throw sharp chips for miles and blades are $$$. Another option may be one of the porta-band saws, either battery or corded, and again resell when you're done with it. Milwaukee, Dewalt, Temu, Vevor, etc. lots of options.
edit
I referred to a cold cut saw, when I was meaning dry cut, but in my defence the cut is still a LOT cooler than an abrasive.

 

[jack stand]

That's a good idea ^^^
I have several Milwaukee Porta bands but have forgotten that for about $150 @ harbor freight will get one. Might not last like my 40+ years ($400 40 years ago) Milwaukee, but it'll do what you want. Neatly with your proper input.

 

[The Cobbler]

the only thing I would add to a horizontal bandsaw, many of them have probably never been tweaked for accurate cuts. would be worth the time to double check everything before you launch into your cuts

 

[Joemctag]

Steel fabrication shops have large bandsaws to do this. They’ll charge you a man’s time for how long it takes him to do it. Maybe 5 minutes per cut and they’ll charge 60 to 85 $ per hour. You’re bringing your material, right?
You could use an angle grinder and 6” abrasive blades but if you’re not pretty experience it could be unsafe and not a pretty cut. You know you gotta clamp the material.

 

[billconner]

I used my DeWalt miter saw with a Diablo metal cutting blade. Thought it might be tough on saw but in fact, no problem and cut like butter. One or two swipes with a file and as clean and square as I could have imagined. ymmv.

 

[bluedog225]

I used my DeWalt miter saw with a Diablo metal cutting blade. Thought it might be tough on saw but in fact, no problem and cut like butter. One or two swipes with a file and as clean and square as I could have imagined. ymmv.

I do have a 25 year old dewalt miter. It’s been through a lot. May give that a shot.

Thanks all.

 

[billconner]

I had good luck with Diablo blade. Just be sure to get one rated for 3/8". Lots of sparks. I did my cutting on concrete patio and aimed towards driveway. It was a once in many years task. Blades are definitely not cheap but much better cuts than I could do with a grinder and abrasive disc.

 

[CraigStu]

Be sure to have good ear protection. Either abrasive or carbide, the noise is terrible. I'd seriously check local sho[ps to see what they would charge. Anything <$150 I have it done.

 

[Dig Doug]

I bought a Steel max chop saw and it works great, but it was $500.

I also have a couple of portable band saws they work great also
I use them a lot more and they can cut just about anything

If you like to tinker w/ steel and don’t want to dump alot of cash Id get a band saw its more versatile.

The deep cut Milwaukee M18 will cut up to 5x5

also a few cut off wheels would cut it, depends on how precise your cuts need to be.

You could use an abrasive saw - cut one side at a time, go slow & cut it a hair longer and trim up with a grinder

 

[Bessy]

4" x 3/8" angle is no joke. I cut some 4"×1/4" two weekends ago with my abrasive chop saw, and it was a process entirely, tripping breakers, just generally hot and slow. Opted to switch to the portaband for another cut, and it was night and day better, though not perfectly square.

Really made me wish for a stationary metal bandsaw and a larger portaband while I'm at it. On my Kijiji list now but I don't typically have great luck finding deals on major tools like that.

 

[GirlnAgarage]

Portable band saw or Evolution chop saw.

Sure, only a "couple dozen cuts" but that will get old real fast with any abrasive.
Personally it'd be my excuse to buy an Evolution chop saw. Ive got a Rage3 and don't ever reget it when it's time to cut a piece if metal or wood.

Buy a dedicated metal chop saw , you will not regret it. You got to cut 4" 3/8ths man. Help yourself, don't suffer.

 

[PCustoms]

@bluedog225 where is the steel currently?

What accuracy do you need on the cut?

If ordering lengths, see if the shop/service center will cut to length.

 

[jhelrey]

I have an Evolution Chop Saw with metal blade vs abrasive. I should have bought it years ago.

 

[no704]

If you want to come to Tempe I’ll cut it for you!

 

[ZRX61]

I just paid the local metal shop to do 6 or 7 cuts like that on their bandsaw, cost me $5.

 

[PCustoms]

I just paid the local metal shop to do 6 or 7 cuts like that on their bandsaw, cost me $5.

Cheap enough.

I used to use 4x4x1/4 angle, that was a bear on a 4x6 band saw and any length substantially outweighs the machine. Try as I might, I still had to cut about 1/4 over so could square it on the mill.

 

[bluedog225]

Edit [NOT] Great accuracy. But want it to look decent. Making brackets for joining some other steel.

I’ve got the steel laying around.

 

[LopezBart]

Cheap enough.

I used to use 4x4x1/4 angle, that was a bear on a 4x6 band saw and any length substantially outweighs the machine. Try as I might, I still had to cut about 1/4 over so could square it on the mill.

I removed the flimsy metal stand mine came with and put the machine on casters right above the floor, and have supports for the metal I'm cutting on either size. This works so long as I can lift the pieces to be cut.

- Bart

 

[PCustoms]

I removed the flimsy metal stand mine came with and put the machine on casters right above the floor, and have supports for the metal I'm cutting on either size. This works so long as I can lift the pieces to be cut.

- Bart

Mine didn't come with a stand, so I made a trapezoid out of 1" square 1/8" wall tube and put it one some casters. Even with multiple rolloff stands I would want to cut a lot of heavy angle.

 

[PCustoms]

Great accuracy. But want it to look decent. Making brackets for joining some other steel.

This means many different things to different people. You talking+/- 1/4" or 0.005"?

I’ve got the steel laying around.

 

[cannuck]

A well set up horizontal bandsaw can make extremely accurate cuts. In my experience, the wider/stiffer that blade the more accuracy you can get. To align, take all the slack our of the eccentric guide wheels and make one cut in square tubing from one side, then roll it 180 degrees and make another close to the first. You will get a tapered offcut, so keep adjusting the aligment until no taper. A 1/2" saw can do this, but hard to get and keep bang on. a 3/4" a fair bit easier and 1" saws can be scary accurate and stable.

Rotary blades can work in aluminum at "skill" saw RPM but in steel you really need a LOT slower speed and preferably controlled downfeed.

 

[MOS3522]

I left my chopsaws for dead when I made this setup (in my case, with the Dewalt 20V band saw).

My cuts are now straight and require minimal deburring and grinding before welding.

 

[ItsNemo]

Dry cut is the way to go...faster, cleaner, cooler, just all around better saws.

 

[bluedog225]

Sorry! Auto correct or blind old man or something like early onset.

“Not great accuracy!”

 

[GrayFlattop]

Evolution chop saw - I wish these were around when I bought my makita abrasive chop saw 35 years ago. Sure, a horizontal band saw would be optimal, but in terms of all-around usefulness, I like the evolution. Portable and easy to find a spot for it.

 

[tarbellb]

On a budget-
circ saw w metal specific blade and a good squared up and clamped piece

Spending money- 4x6 bandsaw or maybe portaband + table

 

[Tundra1]

Are you buying the material or re-using? The suppliers I've worked with will cut to length you specify.

 

[bluedog225]

I’ve got the material already.

 

[mike93lx]

Are you sure you can't get the result you need with an angle grinder?

 

[DAVE94LIGHTNING]

Evolution chop saw 14” blade will cut 4x4 like butter. It comes with a multi metal blade that works great on mild steel.

 

[nerraw117]

I bought a 14" vevor. Probably a evoluton knock off for $200 on amazon and it is amazing. You will hate an abrasive blade if you ever use a dry cut saw.

 

[cannuck]

I bought a 14" vevor. Probably a evoluton knock off for $200 on amazon and it is amazing. You will hate an abrasive blade if you ever use a dry cut saw.

If I was a hobby user I would not hesitate to go Vevor. As a light industrial user, though, I would be looking at Evolution as MUCH cheaper than industrial brands (I have 4 band saws plus access to 2 x 1 1/2" ones, so no need). CAUTION, though: the Vevor knockoff is of the cheap vise Evolution that up here is sold for $ 1,200 by Air Liquide, but IIRC $400 by Home Depot. Princess Auto will sell you the high end vice Evolution for the same $1,200 you pay for the low end version at AL.