Straight cuts in bar stock

[RickP330]

Hi guys,
I'm working on a project and it's getting ridiculous. I don't often do this, but I have to cut a 1" x 1/4" CRS bar into lengths. This is just a mechanics shop, not a production facility and I've tried an air saw, cut off wheel, hacksaw ect. It gets the job done but no two pieces are the same and it's really frustrating me. I can't even figure out a way to square it all up once I'm done. I only have a dozen or so cuts to make.

Do you guys have any hacks with simple mechanics tools to make production style cuts? Yeah, a cold saw would be great but space and limited need for one is a problem....

Rick

 

[inphx]

i use the hand held saw but this is on my nice to have list. https://www.harborfreight.com/universal-portable-band-saw-benchtop-stand-59640.html

 

[PCustoms]

Mark the cut square, cut it (hacksaw, grinder, bandsaw).

Use belt sander and guide to square up and get it right to length.

If you scibe a line you can get pretty dead nuts this way

 

[Wamsutta]

Circular saw with a metal cutting blade will get you pretty square if you scribe a line.

You're going to want the bar stock fully secured in a vise or clamped down to a table.

Eye protection is mandatory in this case. Face protection would be good too.

 

[zimman]

I have a porta band from HF. Cut a smidge long and use a belt sander to clean up the cut to length.
Zim

 

[jayemm]

Circular saw with a metal cutting blade will get you pretty square if you scribe a line.

You're going to want the bar stock fully secured in a vise or clamped down to a table.

Eye protection is mandatory in this case. Face protection would be good too.

I think some ear protection wouldn't hurt either.

 

[MOS3522]

Used to do it with a portaband and a cutting arm rig, but it was never straight enough. I ended up buying a cold cut saw.

 

[Not Bob]

Swag table, HF saw, 1.25" bar. pretty straight.

 

[larry4406]

Mark the cut square, cut it (hacksaw, grinder, bandsaw).

Use belt sander and guide to square up and get it right to length.

If you scibe a line you can get pretty dead nuts this way

This is what I do.

I cut a little “long” so I can sand/grind to the line.

 

[RickP330]

Mark the cut square, cut it (hacksaw, grinder, bandsaw).

Use belt sander and guide to square up and get it right to length.

If you scibe a line you can get pretty dead nuts this way

Yeah, belt sander is it. Mine died a long time ago, maybe time to fix that....

Swag table, HF saw, 1.25" bar. pretty straight.

Damm, that's awesome....

 

[strength_and_power]

Is this a one time thing or going to be a project that keeps coming up?

What kind of tolerances are you trying to hold? A straight cut isn’t going to mean much of the surface you are building on is best to hell and not flat.

Got any friends with a band saw that like beer?

 

[Hannahranga]

HF has a 2" baby chop saw, tbh I'd find space to stash a full sized chop saw but also I'd probably use it more than you.

 

[LopezBart]

A carbide scriber, vice, hacksaw and a good file will allow you to get pretty close (+/. 005) easily. Obviously, a belt sander, band saw, etc. will speed the work, but this can be done quite satisfactorily w/ simple hand tools and a modicum of care.

 

[RickP330]

I'm looking for a solution that does not require purchasing new tools, but that never really works out, does it?

What I really need to consider which tool if I add one is most versatile for other jobs as well. I usually farm out my metal work, but this job is so small it's a shame to waste favors on it - and I probably need a little more versatility in the shop.

Space is at a premium for me, and the work is mostly automotive related. No tolerance, I just want it look professional and not like a child with a hacksaw. So it seems like:

* Some kind of 4" belt sander or the like.
* Portable band saw with a table.
* Small chop saw.

Any other ideas and which might be the versatile? I'm leaning towards the belt sander....

Much Thanks, Rick

 

[PCustoms]

I'm looking for a solution that does not require purchasing new tools, but that never really works out, does it?

What I really need to consider which tool if I add one is most versatile for other jobs as well. I usually farm out my metal work, but this job is so small it's a shame to waste favors on it - and I probably need a little more versatility in the shop.

Space is at a premium for me, and the work is mostly automotive related. No tolerance, I just want it look professional and not like a child with a hacksaw. So it seems like:

* Some kind of 4" belt sander or the like.
* Portable band saw with a table.
* Small chop saw.

Any other ideas and which might be the versatile? I'm leaning towards the belt sander....

Much Thanks, Rick

What are you using these pieces for and how many do you need to cut?

 

[K13]

I can't imagine not being able to cut 1' x 1/4" bar stock to a pretty accurate length with any of the tools you listed. At least to the point that a quick file job wouldn't clean them up. It sounds like either a issue with how you are marking them or just practice needed in using the tools. Are you scribing the cut lines or marking them with something like a sharpie where you have a line that is 1/8" wide?

 

[RickP330]

I am building a spot-welding cart. The carry all is done and now I have added a platform and foot switch operation option. These parts are for the foot switch. I had all of the parts laser-cut and CNC bent, but I forgot two parts for a linkage. Next to the laser cut parts I just need something nicer than what I can do by hand. Plus, I need a dozen or so parts for a test fixture I am working on. This thing is already taking up a lot of real-estate in my shop, but I have a lot of work planned for it....

 

[no704]

Jigsaw with a good blade is what I would probably use if i had to do it with hand held tools.

 

[PCustoms]

I am building a spot-welding cart. The carry all is done and now I have added a platform and foot switch operation option. These parts are for the foot switch. I had all of the parts laser-cut and CNC bent, but I forgot two parts for a linkage. Next to the laser cut parts I just need something nicer than what I can do by hand. Plus, I need a dozen or so parts for a test fixture I am working on. This thing is already taking up a lot of real-estate in my shop, but I have a lot of work planned for it....

So you need two pieces and then never again?

Sharply mark it (hell a razor blade will mark it), Cutoff wheel proud of the like then a grinder to work your way to the line.

Sounds like a technique and not a tool issue...

 

[alfadan]

That's the nice thing about a hacksaw. You go slowly enough to see if you're veering off. Don't shove your whole body into it like you're John Henry trying to beat a steam engine, and let the saw do the work.

 

[tarmy]

This…or as mentioned grinding followed by grinder with flap wheel.

 

[RickP330]

So you need two pieces and then never again?

Sharply mark it (hell a razor blade will mark it), Cutoff wheel proud of the like then a grinder to work your way to the line.

Sounds like a technique and not a tool issue...

Seriously? You guys are supposed to talk me into spending massive amounts of money on tools - what's going on here?
RP

 

[PCustoms]

Seriously? You guys are supposed to talk me into spending massive amounts of money on tools - what's going on here?
RP

Idk, I would have wanted the job done this morning so would have used what I had available.

But



A Bridgeport would work
Best option would definitely be a laser table. You already paid someone else to laser parts for you? You should be ashamed

 

[OccupantRJ]

Clamp a piece of steel on the cut line and run a grinder cutoff wheel alongside it as a control guide.

 

[Beerhippie]

There's a trick to making a nice, square cut with an angle grinder and cut-off wheel: Scribe your line using a good square. Now carefully make a few very light passes on the off-cut side of the line with the cut-off wheel to establish a groove. Now the wheel will want to follow the groove as you finish the cut.

You'll be staring straight down the cut-off wheel while you do this, so wear a full-face mask--and a good one--and safety glasses/goggles. I'd advise a good, heavy jacket with the collar buttoned up. I use my welding jacket. Pulling pieces of cut-off wheel out of body parts is a PITA.

Keep in mind that having the sparks coming back at you means the angle grinder will kick away from you in case of a bind. Best advise I ever had about using an angle grinder. It's counter-intuitive to have the stream of sparks shooting right back at you, but it beats hell out of kick-back injuries.

I do this when I need a fast, straight cut and don't want to set up for and clean after up a guided plasma cut.

 

[drmarkr]

Seriously? You guys are supposed to talk me into spending massive amounts of money on tools - what's going on here?
RP

Since you asked, and since you're a legitimate member of this forum, get in gear and pick up a horizontal bandsaw, a portable M18 or M12 bandsaw, a 12-in disc/ 6-in belt grinder, a set of proper squares, and get after it!

You're welcome.

 

[RickP330]

Since you asked, and since you're a legitimate member of this forum, get in gear and pick up a horizontal bandsaw, a portable M18 or M12 bandsaw, a 12-in disc/ 6-in belt grinder, a set of proper squares, and get after it!

You're welcome.

Thank you! That's what I'm talking about!
RP

 

[RickP330]

Wow,
That's nice.....

 

[Crazyjake8493]

Horizontal bandsaw and a stop for repeatable length.

 

[The Cobbler]

maybe practice with an angle grinder & cut off wheels?

even if you cut it long, you should be able to scribe some square lines and grind up to them , sufficient for what you're building .
clamp the 2 pcs together while grinding & they will end up the same length ( within reason)

some years ago I bought a miter base for angle grinders , thought it was the cats *** at the time. in hindsight I very seldom use it .

 

[zimman]

I can't imagine not being able to cut 1' x 1/4" bar stock to a pretty accurate length with any of the tools you listed. At least to the point that a quick file job wouldn't clean them up. It sounds like either a issue with how you are marking them or just practice needed in using the tools. Are you scribing the cut lines or marking them with something like a sharpie where you have a line that is 1/8" wide?

File? What is this file thing you speak of? LOL
I was going to start a thread and talk about why folks use all these electric and battery tools instead of a file.
Zim

 

[Beerhippie]

File? What is this file thing you speak of? LOL
I was going to start a thread and talk about why folks use all these electric and battery tools instead of a file.
Zim

One, lazy.

B) Boss man ain't paying me to use a hacksaw and file. It's why he paid for power tools.

 

[zendriver]

Circular saw and a speed square

 

[RickP330]

One, lazy.

B) Boss man ain't paying me to use a hacksaw and file. It's why he paid for power tools.

Well,
A hacksaw and file it is. Didn't come out too bad, but power tools are nicer....
RP

 

[tarbellb]

Good to see you knocked it out

Now go grab a handheld bandsaw for next time

 

[RickP330]

Good to see you knocked it out

Now go grab a handheld bandsaw for next time

Yeah - Job is done and it came out very nice. Hand hacksaw and file with a angle iron straight edge. What did we learn? I need the following:

Milwaukee 6232-21 Deep Cut Portable Band Saw $430
JET Benchtop 6" x 48" Belt & 12" Disc Sander, 1-1/2 HP, 115/230V 1Ph (JSG-6DC) $1,870
Swag Table with foot switch and Miter gauge $270

Total =

 

[tarbellb]

Yeah - Job is done and it came out very nice. Hand hacksaw and file with a angle iron straight edge. What did we learn? I need the following:

Milwaukee 6232-21 Deep Cut Portable Band Saw $430
JET Benchtop 6" x 48" Belt & 12" Disc Sander, 1-1/2 HP, 115/230V 1Ph (JSG-6DC) $1,870
Swag Table with foot switch and Miter gauge $270

Total =

Ha yeah goals right. Learning to do it the harder manual way is always a good lesson, makes you appreciate the quicker or more accurate way later in life

If it was my money.....

HF corded deep cut band saw $100
DIY steel top $20
eBay foot pedal $ 25
HF 12" disc grinder $200
HF Hercules 2x48 Belt $300

ps. that JET combo sander has a lot of plastic parts, I would look other options