Are my steel cutting expectations unrealistic?

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I just purchased a Rage 2. Its heavy, lots of metal and almost no plastic on the thing which is good. But the fit and finish is worse then harbor freight. So I have taken my square out and its "fairly" close out of the box once i fixed the fence and took off the metal plate on the bottom which was cuasing the whole base to rock.However, the cut looks like ****....I have tried going fast, slow and medium speed through the metal. Maybe im expecting to much coming from the woodworking world, i dunno. I am just starting to mess around with metal. Those of you with Dry Cut saws, does your cut look like below. The picture really doesn't do it justice. The bottom part of the sqaure tube stick out quite a bit.
Reply:That's weird, is the work moving around in the clamp or something? What's with the sawtooth profile? is the blade worn out?Welding/Fab Pics: www.UtahWeld.com
Reply:My dewalt cuts cleaner than that. I get an almost milled finish on the cut edge.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Either the work piece is not clamped down good enough and can move or something in the blade structure is loose. Maybe the blade securing bolt is not tight. Or something in how the blade is held has too much slop in it. That and maybe trying to force the cut with too much pressure.The blade is able to move sideways in relation to the work piece by some manner. You should be able to cut about like a wood chop saw in terms of a square cut.Check the blade has no slop and runs true, there is no ability to move side to side for any reason. If that is eliminated, prime cause is the work piece is not clamped firm enough. If you are cutting it in a vertical manner, try putting it horizontal, the shape of it might not be easy to clamp up firm in the vertical, not enough clamp surface available in contact. Process of elimination. Does it do it on other more regular shaped pieces that have full clamp surface applied?
Reply:that choppy looking edge is from the blade vibrating/bouncing around. Have you bolted the base down to a table yet?  Anything you can do to replace, modify or beef up the original clamp, fence and hardware that might give you a better chance of a good cut. With time spend, you'll learn the sweet spot of how the saw/blades like to cut. mine liked a very slow start through the leading edge of the steel, then it would speed up through the center of the tubing and then slow, low pressure as the blade cut through the bottom wall of the tubing. just be attentive to what you saw/blade likes given the material you are cutting. brand new operators to this saw is going to be some of the problem getting good cuts. Im just very down on that product. Try your best of bolt down the saw and tripple check the fence, clamp and hardware. replace with grade 8I have a milwaukee dry cut saw and recently bought a rage evolution saw blade. big mistake. a very crappy product. would never buy their product again. watch for the carbide teeth just disintegrating and falling off.this is what you should expect out of any dry cut chop saw. id would stick with dewalt, milwaukee or makitaafter many many years of full time work, my saw was cutting like crap. I took it all apart and built it up with all new small parts, new base, new fence. all about $90. very cheap. the saw cut like brand new again and i was very happy.then 30 days later, i finally bought a real saw. $7k well spent. have not used the dry cut since.
Reply:something is definately moving. either the blade is lose or the piece isn't clamped properly. I've got a rage 3 and my cuts are much cleaner than that.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:I have the same saw. I had to loosen bolts and add shims for a square cut. The saw cuts fine.Like stated, check all the hardware too. I hope you got it cheap ! That's why I bought it.
Reply:I think the problem is in hte arm that swings down. If i grab it and yank on it, it moves on the pin. There is slop in it. You dont really notice it though cause the spring holds it tight against the pin. Im wondering if its somehow moving while im cutting.There is no way the clamp could be moving. The clamp is heavy duty and nice and tight. I actually got the best cut when i pushed the saw hard. I knew i should have bought the Makita. Originally Posted by ThorsHammersomething is definately moving. either the blade is lose or the piece isn't clamped properly. I've got a rage 3 and my cuts are much cleaner than that.
Reply:Icecactus, can you return that saw? A dowel pin and a spring isn't a legit pivot.Last edited by Jimmy_pop; 10-03-2012 at 04:46 PM.
Reply:I use a Steel Max cold cut saw with the Evolution blades and it cuts square every time.  I use it in the field constantly set up on gravel, cement pads, and makeshift tables and never had a problem.  I would say that the saw is the problem.  Just my two cents
Reply:The Milwaukee doesn't have any flex dependent on where it's sitting.. I've lost the rubber booties on 2 feet and hasn't caused any problems with cuts..Pull the spring and inspect the pivot.Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:Thanks everyone for the pics and info!Just had a buddy over and we were inspecting the saw. Looks like there is a bit of slop in the arbor the comes out of the motor. You can grab it and hear it moving back and forth. I think thats what causing it. I am going to return it and just get the better tool like i should have in the first place.I am thinking either Makita dry cut or the Grizzly 5x6 swivel band saw http://www.grizzly.com/products/5-x-...vel-Head/G9742leaning towards bandsaw after using this dry cut...
Reply:You can come cut with my Milwaukee 6190 if you're close to Phoenix.
Reply:Same gies for my dewalt. I'm in Glendale az.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Wow, thanks for the offer guys! I ordered the 5x6 Bandsaw today. Should be here some time next week. Eventually I will also probably purchase a dry cut, but i figured this mitering band saw will be a bit more versatile. Since i can only have one at the moment, i choose that one. Hopefully i made the right choice. Moving the material to do 45* angles really bothers me for some reason and with the swivel band saw i wont have to.How did you guys know i was in Phoenix area?
Reply:Congrats on the saw. Just a wild guess based on your cactus reference in your site handle.
Reply:Congrats on the band saw. Give some feedback on it once you have it. I'm looking for one and I like "real world" opinions. I was thinking about a vertical but I really have no use for vertical because any cuts a vertical band saw can do I can do faster with my CNC plasma. So in intrest in saving $ a horizontal would wort fine for me. So please post a review. Thanks.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Using a band saw is a great choice. Proper clamping should be followed to avoid those previous cuts you’ve had. What band saw did you buy? I mean, what brand?