Best tool(s) to cut .25" mild steel shape cuts on a regular basis

[spdwaver]

I need a tool that will be best for reliably cutting .25" mild steel shape cuts, on a very regular basis. These shapes will range from squares (I am currently using my circular saw with a .125" or .1875" blade) to shape cuts that are irregular in form.

I have designed parts for the heavy equipment industry in the past using nesting software that interfaces with a cnc plasma / oxy/acetylene torch on a 96" x 240" water table, but I do not have access to such and now must figure out a better way of making these cuts in a small workshop (my garage) using more common tools.

I recently fabbed up a set of Metal Tech-style spacers and used everything from cut-off wheels on a 4.5" angle grinder to a sawzall with a steel blade; but these are all largely inefficient and are not the most practical means by which to move on to a more productive environment.

With the need to take it up a notch, which tool or tools would be best to cut up to .25" on a regular basis?

Thanks in advance!

 

[fj40charles]

Get a Iron Worker. Something like this:

http://cgi.ebay.com/BRAND-NEW-EDWAR...tem&pt=LH_DefaultDomain_0&hash=item2c53c1a529

Other brands: Scotsman, Pirana, Baleigh.

 

[PAToyota]

I went for years with a grinder and a HF horizontal bandsaw. The older bandsaws came with a table and you could position the saw vertically to do a bit of cutting. Not sure if the ones they sell now still have that feature.

All depends on what you want to spend. An ironworker would be nice, but I don't have the room or money for one.

 

[spdwaver]

The Iron Worker is currently out of my range of affordability, but I imagine three or four used tools and about five times the space ought to replace what one Iron Worker can accomplish.

Thanks for the replies.

 

[hedgehog23]

regular plasma cutter , make up templates for fast clean cuts.

 

[cruiserhead]

Plasma cutter.Get the biggest one you can afford,that will cut at least 1/4".Cutmaster 51 by Thermal Dynamics

David

 

[spdwaver]

Plasma cutter it is.

Thanks for all the replies!

 

[calstyl2]

Pirate4x4 has some good vendors for plasma cutters.

 

[fj40charles]

Pirate4x4 has some good vendors for plasma cutters.

I'd buy a used Hypertherm before considering the imports.

Personally, I would not buy a new chinaman made plasma cutter. YMMV, but many people have had reliability and support issues buying chicom.

Jim Colt of Hypertherm is on this board and is VERY helpful and knowledgeable.

If you plan on welding the cut pieces, be sure to grind off the dross before you try to weld.

 

[vtcruiser60]

I picked up a used Milwaukee metal cutting bandsaw and use it for 85% of my metal cutting now. I use a 4.5 inch angle grinder for most other cuts. The bandsaw is very nice to work with....and cheap money relative to a plasma cutter....which would be nice.

 

[fj40charles]

I picked up a used Milwaukee metal cutting bandsaw and use it for 85% of my metal cutting now. I use a 4.5 inch angle grinder for most other cuts. The bandsaw is very nice to work with....and cheap money relative to a plasma cutter....which would be nice.

Good point. I use a Milwaukee 6236 portable band saw for most cutting. I like the idea of very little cleanup compared to O/A or plasma cutter when you need to weld. Plasma cutters have their place, but I don't use mine much.

 

[vtcruiser60]

Good point. I use a Milwaukee 6236 portable band saw for most cutting. I like the idea of very little cleanup compared to O/A or plasma cutter when you need to weld. Plasma cutters have their place, but I don't use mine much.

yep...and they are not loud either. Angle grinders rattle my brain..despite ear plugs. Same with a chop saw. More and more, I find myself reaching for quiet solutions...maybe I am getting old.

If you have fuel around or anything flammable, the bandsaw is nice as well--no sparks. Buy Lenox bandsaw bands...they are the best I can find and worth their money.

 

[yotawheeler]

gunna go another vote for plasma cutter...i use mine a fair bit for my fab, i have a hypertherm cutmaster 1000, between that and the cutoff saw i hardly ever use my bandsaw....which cuts slow...and is NEVER square, no matter what blade or lube or or or that i use. also, if you learn how to use a torch (or plasma) and get good at it, there is little to no slag and no pre weld clean up

 

[spdwaver]

I picked up a used Milwaukee metal cutting bandsaw and use it for 85% of my metal cutting now. I use a 4.5 inch angle grinder for most other cuts. The bandsaw is very nice to work with....and cheap money relative to a plasma cutter....which would be nice.

I was looking at these, and had a chance to get one at a good deal - but passed, not knowing if it would do the job. Maybe I will revisit this and try it out.

 

[jimcolt]

Heres a pic of some cuts done with my Hypertherm Powermax45 plasma on a 4 x 4 cnc table. If I want to cut by hand I unplug the machine torch and plug in the hand torch....can sever to 1-1/4", torch is designed for drag cutting and for guiding along a template.

Jim Colt

 

[spdwaver]

Heres a pic of some cuts done with my Hypertherm Powermax45 plasma on a 4 x 4 cnc table. If I want to cut by hand I unplug the machine torch and plug in the hand torch....can sever to 1-1/4", torch is designed for drag cutting and for guiding along a template.

Jim Colt

I really do miss the days of being able to draw/post my items on a PC, walk out into the warehouse, throw a sheet of steel on the table and make all the shape cuts I want.

My goal, however, is to test the feasibility of making shape cuts in my garage - for nowhere near the expense of a nice table setup - with hand tools, if possible. I will more than likely go this route, but for starters, hand tools are gonna have to cut it, pun intended.

 

[jimcolt]

Well, this one is in my garage! The Powermax45 plasma is about $2k, the cnc machine and software is $10k.

If the max you need to cut is 1/4" you could use the Powermax30, which is around $1000. Just pretend your hand is the cnc machine, and your mind is the nesting software!

Jim Colt

 

[spdwaver]

Well, this one is in my garage! The Powermax45 plasma is about $2k, the cnc machine and software is $10k.

If the max you need to cut is 1/4" you could use the Powermax30, which is around $1000. Just pretend your hand is the cnc machine, and your mind is the nesting software!

Jim Colt

$1000 is not so bad. Now I have more reading to do.

 

[jimcolt]

Check out this link.....plenty of reading and a few videos as well.

Powermax30 Plasma Cutting System | Plasma Cutter | Hypertherm

Jim

 

[yotawheeler]

or....look used i picked up my hypertherm cutmaster 1000 for $800 and it works great, i love it