Metal cutting tools recommendation?

[downsizingnow48]

The thing about metal working is you will often find you need another tool to do what you really want to do.

For your next tool up from the angle grinder I would also think of a bandsaw or a dry cut chop saw.

Not mentioned yet but an extremely useful item is some kind of belt sander / belt grinder. For deburring, softening edges, putting a radius on corners, tidying up a ragged O/A or plasma cut, many things. You can spend a lot on dedicated belt grinders, but for years I made do with an upside down Bosch handheld belt sander in a DIY frame with a ceramic belt either 60 or 120 grit depending.

 

[grsthegreat]

I love my plasma cutter. Its about 8-10 years old and I still use it for many projects. I had to cut some 12g into a 24 diameter circle with a 2 center cut hole for my 3 point fence wire unrolled. Only took a few minutes to manufacture... mind you I have a plasma table so I cheat a bit.

 

[Seven Gables]

I like to use my stationary Ramco metal cutting bandsaw on the big stuff., think it handles up to 12-13" horizontally. Milwaukee deep cut for smaller stuff, very handy. 41/2" angle grinder and even a quality air die grinder with abrasive wheel for cutting and grinding smaller items. One thing that I can't emphasize enough if your new to the metal working game is always always wear a set of eye goggles when using a grinding wheel. There is just about nothing more miserable than a a tiny metal flake or even the metal dust in your eyes. Ask me how I know. PS big Barn that Lenox wheel looks like something I need to try, thanks for the tip. B

 

[ArlyA]

For one, I'd suggest a cordless bandsaw. Like this one by Makita. Gee whiz are they handy.

https://www.amazon.com/Makita-XBP02...less+bandsaw&qid=1559004779&s=gateway&sr=8-10

Any cutting and fitting I've done so far has been with a Harbor Freight 4 1/2" angle grinder using a cutoff wheel. It works well for the rough cutting I've been doing. For example, yesterday I welded a small tab made from 3/16" flat stock, on a broken 22 rimfire spring actuated/knockdown target reset paddle. Exact fit was not important. I just needed a 3/4" x 3/4" piece from a piece of flat stock, roughly in the shape of a square. Cut it with the angle grinder.

I suspect I will get to projects where I want to fabricate mounts or fixtures out of 1/8th, 3/16", or 1/4" mild steel, where a close fit between two parts is needed.

Is there a decent, one tool cutting solution for a casual/occasional welder?

 

[chim]

DeWalt 20V cordless tools have a special place in my heart. Jig Saw does well up to about 16ga. Recip saw does bigger stuff. Grinder with Harbor Freight cutoff wheels works well and is especially handy for cutting stuff in place. Band saw makes short work of pipes, channels and square tube.

Cord-connected tools are a Harbor Freight 6X4 horizontal band saw, the old recip saw and just last year I added a Hypertherm Air 30 plasma cutter. The Air 30 cuts everything I get into, plus it has its own air and and can be used on thinner material with 120V power.

 

[Smokeydog]

For one, I'd suggest a cordless bandsaw. Like this one by Makita. Gee whiz are they handy.

https://www.amazon.com/Makita-XBP02...less+bandsaw&qid=1559004779&s=gateway&sr=8-10

Bandsaws any size are helpful. Multitool belt grinder is on of the most used tools in the shop.

 

[spitter]

If you don't want to spend much money a angle grinder with a zip wheel is pretty much all you need . Not the best at anything but there is nothing you cant cut with it. When were on a job and don't have the rite tool we just grab a angle grinder and a zip wheel. Next cheapest is a chop saw and a abrasive blade cut metal studs with it for years. Cuts everything not perfect but for $150 dollars and blades are like $5.00 a piece it can't be beat.:drink:

 

[lennyzx11]

Yesterday I grabbed my DEWALT 20 v cordless 4 1/2” grinder with a thin cutoff wheel and used it on the garden gate to cut the protruding screws off.
A few days ago I used my cordless Milwaukee deep bandsaw(portaband) to cut a piece of 1/2” plate steel. And some 2” square stock for a receiver gadget for my box blade.
Then an old corded craftsman 4” angle grinder with a wire wheel cup has cleaned stuff up for at least 25 years for me that I can remember.
Another corded DEWALT angle grinder has flap disks on it which I never knew about until reading about on here. Best thing since Butter!
Then the Hypertherm Air30 plasma cutter for some aluminum thin metal for a patch was used last week.
I’ve wanted a chop saw for years but can’t justify one with all I have now that does the jobs I need done.
That DEWALT cordless angle grinder with a thin cutoff wheel sure makes life nice for stubborn bolts and quick cuts around here though. I’m not even sure where my hacksaws are right this minute.
Lenny

 

[TractorGuy]

Don't rule out a cordless reciprical saw. I find myself using that more and more for the cuts I used to use my bandsaw for. Get your piece level in the vise and you can get pretty straight cuts with them. I recently tried some HF metal cutting blades and found them to be pretty good.

I did like my 4x6 bandsaw but it took up more space than the HF welding cart and plasma cutter. The plasma cutter is more portable and makes short work out of long cuts. I recently sliced one side off a piece of 4" angle that was 5' long in about 2 minutes or less. Try THAT with a bandsaw.

 

[yomax4]

At some point many hobby guys will likely aquire all of the above. I couldn't imagine not having a dry cut saw ( or 2 ) a few angle grinders with various wheels, Plasma and Oxy-fuel, Band saw, shear and nibbler. Enjoy.