How do you cut metal for finished projects?

[joshuabardwell]

I may add the plasma for Fathers' Day :thumbsup: it sounds like nearly everything I would do with the band saw I can do with the plasma cutter.

You should totally get the plasma if you want it, but I don't agree with this conclusion. Plasma can cut bar stock about as good as a bandsaw, but plasma isn't great for tube or angle, because of the difficulty getting a square and even cut. You basically have to work your way around the perimeter, which introduces a lot of potential for inaccuracies. A bandsaw excels at accurate, repeatable cuts in bar, tube, and angle stock.

 

[Ted Summey]

I have a 14" abrasive cutoff saw for bar, pipe, angle etc. seems like with that AND the plasma cutter a bandsaw would be redundant.

 

[joshuabardwell]

I have a 14" abrasive cutoff saw for bar, pipe, angle etc. seems like with that AND the plasma cutter a bandsaw would be redundant.

I think you're almost right. The bandsaw makes cleaner cuts, is quieter, and is more precise. It doesn't make sparks or cutting dust either. And the metal coming off it is cool to the touch. Also, I am pretty sure bandsaw blades are a better value than abrasive wheels, in terms of number of cuts.

 

[Ted Summey]

Joshua, you are probably right on the value as far as number of cuts of the bandsaw over abrasive cutoff. I just have the cutoff saw. The cost of a stationary bandsaw AND a plasma cutter would b prohibitive. Plus space is becoming an issue. I have some other equipment in my shop besides the metal wokng tools. So whichever way I go, I have to choose one machine - bandsaw or plasma cutter.

 

[yomax4]

I like all of the above. band saw is much needed, Torch can never be totally replaced. I like the cold cut carbide teeth chop saws better than the abrasive type. Cutting circles, Bevels, Gouging etc. on Aluminum, Stainless, Rust Grease paint it's nice to have a Plasma. I'm lucky enough to have all of these and I use them all extensively. Get as many toys as possible. You will use them all.

 

[bikerdib]

I like all of the above. band saw is much needed, Torch can never be totally replaced. I like the cold cut carbide teeth chop saws better than the abrasive type. Cutting circles, Bevels, Gouging etc. on Aluminum, Stainless, Rust Grease paint it's nice to have a Plasma. I'm lucky enough to have all of these and I use them all extensively. Get as many toys as possible. You will use them all.

Wise talk that. Like I said previously, I have a plasma cutter, O/A torch with various cutting and welding tips, portable band saw, horizontal band saw, reciprocating saw, 14 inch abrasive chop saw, 8" hand grinder with cut off wheels, 4.5 inch grinder with cut off wheels, 4" air grinder with cut off wheels, 3" air driven cut off tool, air driven reciprocating saw and even a hacksaw. I use each and everyone, they all have a use and place.

 

[petes]

I used arm power and a hack saw up until just a few years ago when I built my boxblade. That wore me out, so bought a used 14" abrasive chop saw at the tail end of the build. It's great except, as stated, the mess, noise, smoke and black boogers after using it. I've also started a few fires with the sparks...

I was fortunate and got a fixer Hypertherm Powermax 800 for cheap (easy fix). I consider it paid for itself on the first project - removing a poorly built and welded on trailer hitch from a motorhome and fabricating a new one. Ability to gouge out welds precisely in tight spots is fantastic, although gouging overhead in tight spots results lots of holes in clothes and skin. I mostly use it to cut plate. Circles are easy - I make a template from 1/8" doorskin 1/4" larger or smaller), clamp in on and cut. It hardly chars the wood, and parts can be handled as they drop. I'd have a hard time justifying buying a new one, but keep using it for things that nothing else would have worked - like cutting curves and circles in 1/8 and 1/4" stainless. I hope to build a CNC table for it some day.

My next acquisition was a BIG (something like 8x12) old horizontal bandsaw (only $75!). I'm starting to use it more and really like the straight clean cuts through tube and angle. I only use the abrasive chop now for thin tube and small angle (<1/4").

A cutoff wheel on the 4-1/2" grinder is handy, too, usually for cutting through a weld or lopping something small off.

I don't have a torch - There have been a few times when I wished I did, but haven't been able to justify it.

I like to tinker and build things - tractor attachments, repairs, etc. and also building some chocolate making machinery (hence the stainless). Most is 1/4" or thinnner, but since I got a bigger tractor I'm going to have to step up to thicker more often.

In order (my opinion)
Hacksaw
Horizontal bandsaw if doing bar angle and tubing >1/8" thick
Plasma if doing plate <3/8" and curves. As stated already, also need lots of air.
Oxy/Ace torch if doing >1/2" plate but need to have a 9" grinder.
Abrasive saw is handy, quick and accurate, but I hate it most of the time. With a proper fume hood/spark catcher it'd probably be #2 on the list.

I still use my trusty hacksaw a good part of the time.