Need advice on cutting lots of angle iron......

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Hey guys,  I have a small business where I receive crates full of product and i need to dispose of the crates efficiently.  The crates are made up of 1/16" angle iron and I need to cut the four legs ( or corners ) off each time I empty a crate.  This way the left over scrap metal lasy nice and flat making it easy to dispose of.  What do you suggest is the best, fastest and cost effective way to do so?  I picked up my milwaukee recip saw and threw a 18 tooth metal blade in there.  It worked, but I dont know how long the blade will hold up.  I was thinking about getting the 14 tooth.....but I though I would post here first.Any ideas would be greatly appreciated.thanks Attached Images
Reply:If your wanting to do it free hand, I'd get an angle grinder and a box of 4" zip cut disks. Fast, cheap, and easy, and you'll have( if you don't already have one) an angle grinder, which is useful for many things. 200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:hope you're getting money for the metal if you're just getting rid of it. Local scrap yard will pay by the pound.My electrician was just telling me they recycle all the wire off cuts they get. He makes about $5000/ year. So it can add up pretty quick.200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:of course i plan on getting paid, lol.........but like i said, i need to figure out how to get the sides cut off so i can maximize space, stack them and cart them away. You really think an angle grinder and 4" cutting blades is the best route?  What does each cutting blade run $$.  Pick them up from HD or lowes ?I did a quick check and found angle grinders come in various sizes as well as the discs.........pro's or cons for using larger discs than 4" as you stated?    Found these real quick.....Bare with me.....I know its harbor frieght.....its the first thing that popped up when i googled the stuff, lolhttp://www.harborfreight.com/catalog...inder&limit=16http://www.harborfreight.com/catalog...=&q=metal+discLast edited by noupf; 06-04-2010 at 09:22 PM.
Reply:Actually, I'd check around for a motor rebulder or electric shop and see if they won't just take them. Boxes and shipping containers are pretty expensive when you have to make them.If you are going to cut them up, bert's got the right call with abrasive disks.Matt
Reply:Well it's your body parts and your money but I never buy anything that's going to get spun at high rpm from Harbor Freight."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:Let's just remember he's not cutting them in a welding shop. There could be flammable material nearby w/ the sparks flying everywhere. I also think the 1/16" angle is gonna pinch the disc and somebody may get hurt when the disc disintegrates. I think I'd stick w/ the sawzall and the 18 tooth blades. I know it's hard to do, but run the saw @ 1/2 full speed. The blades won't heat up so easy.                            JMHO,                                      MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Yep, I would go for a better angle grinder.  I have one from Horror Fright that sounds much like a klaxon when running.  That's the one I loan out....Larry "I feel for the man who cannot spell a word more than one way."  by Mark TwainLincoln AC225-SLincoln Weldpac 100 Miller Matic 180 (auto set)Miller Spectrum 375 ExtremeMiller Spoolmate 100Victor Super Range II
Reply:If the plywood sides will be out when the cutting commences, then I would chop them up with the plasma.  Fast, easy and costs practicly nothing if you already have air in the shop.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:get a 7 1/4" evolution saw with a steel cutting blade.  it will cut those as fast a a circular saw will cut through the wood...  My buddy buys and sells import ATV's from China and they are shipped in boxes just like that...     Plasma cutter or OA torch will be fastest of allTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:How much is the solution worth? A metal cutting circ saw or a portable band saw will work excellent and cost $200-$400+ - and they're a bit heavy but that may not be an issue. Need a good quality sawzall to do "production" work like that. Heat kills the cheap ones; re-lube the nose bearing every 10 hours of use. Guess you could get the blades down to maybe $3/pc (? been a while since I bought any). Could also try a jig saw with a metal blade - don't recall what the blades cost. Again you'll use it up quick if it's not a good heavy machine, but "good heavy" jig saw is a lot lighter than anything else 'cept a grinder (sparks all over) and maybe that would help... Also w/a jig saw you maybe don't have to hold onto the work quite as tight; D-handles are easier to hold for most people.Metabo grinder's what $200+ Good jigsaw maybe about the same. Break a tool and it'll cost you $$$ just in time and annoyance so the top machines are usually worth it easy if you do any work with them. Sawzall and jigsaw are probably the safest by a long shot; if your workers are no smarter than they ought to be that might swing it right there; grinder would likely be next safest but you gotta watch the sparks and keep the shields in the right position and wear glasses.This from a plumber that uses all the above except the circ saw to demo out for remodels. Lots of cutting and for us the sawzall with the nose you can get into almost any place is king.Rufus
Reply:hi, don't know how this would work for insurance concerns but, you may find someone to do it for you just for the steel. This depending on the way he does it and how comfortable you are with him. There was a local guy that would get all the plywood he wanted from shipping containers for on crating them. this guy was neat, clean, and professional.it worked out great, it all depends on people and insurance today. just a thought.
Reply:I am not sure where to find them but I have seen hand held shears that cut 1/16 stuff.( sorta look like bolt cutters) They even have them air powered.Way faster than sawing or grinding and no sparks. Call Grainger or Mcmaster-Carr.tractor,loader.dozer,backhoe,and all the tools to keep em movin
Reply:Originally Posted by noupf. . . The crates are made up of 1/16" angle iron and I need to cut the four legs ( or corners ) off each time I empty a crate.  . . .I picked up my milwaukee recip saw and threw a 18 tooth metal blade in there.  It worked, but I dont know how long the blade will hold up.  I was thinking about getting the 14 tooth.....but I though I would post here first.Any ideas would be greatly appreciated.thanks
Reply:I like Makita grinder myself because of the small body diameter( = easy to hold one handed). I said 4" because if it catches an edge, it's a bit easier to control than the bigger grinders and disks. I don't know anything about your tool experience.  Yes, I agree about not knowing about the flammability of your surroundings. So for no/less sparks, a reciprocating saw may be better. I think the bolt cutter like shear 1-800 spoke of would be the cheapest long term. Knowing your budget would help. Though if you're looking at HF, I'll guess it's budget conscious. That's also why I recommended the 4" grinder and disks. If you've got money to play with then Desert is right, plasma is the bomb, and you wouldn't need a big one either. Is the plywood removed before cutting? If not and you're not surrounded by flammables, then the zip disk, reciprocating saw, even the plasma would work. Just wear a respirator and leather gloves to tamp out the small burns in the plywood 200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:thanks for all the replies everybody.  1)  I usually will need to cut up two or three of these crates a week.2)  the wood comes out before I cut the metal.3) there is actually an oil truck that is stored in the same bulding that I work in, so i guess sparks being kept to a minimum would be a good idea, lol4) i think the reciprocating saw is probably the best option.............so my question is what is the best kind of blades to use?  I dont know much about them, I've seen bi-metal blades, metal blades.........14 tooth, 18 tooth, 6 inch, 9 inch.........5) any tips on brands, style of blade and where I could them on bulk ( 10 pk, 20 pk ),6) any idea how long a metal cutting blade would be good for before it dies and doesnt cut any longer?thanks for all your help !
Reply:My first thought is  that if you are getting a product in these angle iron frames on a regular basis then I would call up that company and make a deal to send them back as complete boxes and thereby lower the cost for your company and theirs. A truck must be going back the other direction.You need to get at the people on top.Get a letter written in Chinese if needed.Last edited by Donald Branscom; 06-05-2010 at 07:46 PM.AWS certified welding inspectorAWS certified welder
Reply:Sawsall will work but a portable bandsaw (I have the Milwaukee) would be much faster and easier.  Goes thru 1/8" x 2" angle like a hot knife thru butter.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:And now it's time for Alfred's 2010 bayonet saw awards:(Drumroll please)Best corded saw:  First place - Best corded power saw, Porter-Cable Tiger Saw - For the 35th year running!(Expect extensive applause and  cheers. Wait for audience to calm before announcing Second Place )Second place - In the corded saw category a very close second is awarded to: Milwaukee SawZallBest cordless saw: First place - Milwaukee conventional Sawzall. (Not the compact folding model.)Second place - Still awaiting judge's delayed decision.Disqualified - DeWaltDemolition metal cutting blade category.In this category, a blade which may cut faster in some specific ideal application but slows with mixed work, or which fails by buckling when cutting at some distance from the saw's shoe is rated lower than a blade which may cut slower but has a strong body which resists folding. In this category emphasis is on long blade life and rapid cuts, over cut quality.Best demolition-type metal cutting blade: First place goes to -  Lenox Lazer  (Prompt audience cheers)Runner up blades - Starrett "King Cut" and Milwaukee "The Torch."Good LuckLast edited by denrep; 06-05-2010 at 09:17 PM.
Reply:Now why was Dewalt disqualified?  Cuz it works so good they must be cheating?  I've used and abused one for a few years now.  I don't even own one with a cord.My name's not Jim....
Reply:Originally Posted by BoostinjdmNow why was Dewalt disqualified?. . .
Reply:I'd use my makita 4131 circular saw on that job. Its the fastest and safest. I even collects most of the chips. Got mine as "factory reconditioned" for about $150
Reply:I can see the wear issue, I have rebuilt mine once.  Cost me about $15 if I remember correctly.  At the time though, I was cutting lots of plaster and sheetrock.  Mostly with the saw pointing up at an angle so the dust was falling into it.  I don't really have any problem with that.  Depending on what I'm doing, I may change the batts almost a dozen times in a day and have yet to lose one off the saw.My name's not Jim....
Reply:I never heard the old standard and dependable O/A torch mentioned,cuts real quick,everybodies got one of these,my very first welding apparatus,brazing with O/A torchMaxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:What about a shear of some kind? Or maybe some large bolt cutters? The angle iron is light gauge. Fast, no sparks.Abrasive wheel chop saw if you will be doing this all the time.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by noupfthanks for all the replies everybody.  1)  I usually will need to cut up two or three of these crates a week.2)  the wood comes out before I cut the metal.3) there is actually an oil truck that is stored in the same bulding that I work in, so i guess sparks being kept to a minimum would be a good idea, lol4) i think the reciprocating saw is probably the best option.............so my question is what is the best kind of blades to use?  I dont know much about them, I've seen bi-metal blades, metal blades.........14 tooth, 18 tooth, 6 inch, 9 inch.........5) any tips on brands, style of blade and where I could them on bulk ( 10 pk, 20 pk ),6) any idea how long a metal cutting blade would be good for before it dies and doesnt cut any longer?thanks for all your help !
Reply:One more for a Port-A-Band.( might even try the HF version for this Demo work)Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by Broccoli1One more for a Port-A-Band.( might even try the HF version for this Demo work)
Reply:Everyone has overlooked the obvious....Only two or three a week? A dependable method with no sparks,no batteries to go dead,no tangled up power cords? Rugged,cheap, and compact?  Hacksaw!tractor,loader.dozer,backhoe,and all the tools to keep em movin
Reply:+1 on the Bandsaw, it will make quick work of the job, it won't be dangerous to anything or anyone around you and you can get a cheap corder one from harbor freight if you are only cutting 1/16" angle iron.  I would get a good quality blade though.  The sawzall makes a lot of noise and the blade could be used as a bayonet.
Reply:Another vote for a porta-band.  Way easier to use than a reciprocating saw and I bet you'll spend less money on blades in the long run.Miller 250x & Lincoln V205-TSmith Oxy-Prop torch
Reply:Originally Posted by SundownIIISawsall will work but a portable bandsaw (I have the Milwaukee) would be much faster and easier.  Goes thru 1/8" x 2" angle like a hot knife thru butter.
Reply:I'd post them for free on Craigslist and see who would just haul them away for you.bob
Reply:Originally Posted by SundownIIISawsall will work but a portable bandsaw (I have the Milwaukee) would be much faster and easier.  Goes thru 1/8" x 2" angle like a hot knife thru butter.
Reply:There is lot's of great advice here BUT how about restating the problem?Try:  "How can I get the most value out of these shipping crates?"Some ideas:-Sell them as is.-Modify them into a more valuable product.-Trade them for goods or services.-Sell the component parts with no cutting.-Etc.The last resort might be dissasembly (cutting) and if you do that try to end up with the most valuable end uses other than just scrap metal which should be the last resort.  Your environment and your pocketbook should be happier.
Reply:....Since you already have the good re-cip saw....I'd go with Lenox or Starrett bi-metal varicut blades 14/18...box of 10 will be a good price..Home Depot, machinist supply or welding supply store. Another good deal would be a port-a-band saw, but pricey unless you need it for other stuff....around $250+...go with same kind of blade...bi-metal vari-cut 14/18....we use them a lot at my metal fab job.Dougspair
Reply:I would go for shears. 8 Cuts per crate; snip snip, no sparks, no screaming motors. 1/16" Angle iron will behave like sheet metal and if it's scrap then distorted cut ends are not your problem.Orion pulse-arc welderStick an O/A too
Reply:Is there a type of hand-held shear available that will cut angle without passing over an end?  I guess I'm not familiar with one.It also looks like there may be a few cuts at the base which a PortaBand way not be able to handle.Good Luck
Reply:Originally Posted by denrepIs there a type of hand-held shear available that will cut angle without passing over an end?  I guess I'm not familiar with one.
Reply:Originally Posted by BoostinjdmYes there is, but you don't want to know what they cost.  It would also fold the angle, which wouldn't be an issue if it's going for scrap.
Reply:Ya but I thought we were talkin' about a snip snip here and snip snip there and a couple of falalas... With some simple manual shear. Originally Posted by AyAyI would go for shears. 8 Cuts per crate; snip snip, no sparks, no screaming motors. 1/16" Angle iron will behave like sheet metal. . . .
Reply:If he's looking to do it on the cheap and only has a few to do a week, a porta-bansaw is to much money, especially if he's just getting scrap prices for the metal, IMHO. Like I said, Zip cut if sparks aren't a problem or your recip. saw with a good blade. Rereading you OP, I'd say you just need to make 4 cuts to take the top off and fold the legs inward. Done like diner. 1/16 angle will fold up easy. Half the cutting labor and double the blade life because you've halved the number of cuts. Hell, once the wood is out, I would be surprised if you couldn't just squish the thing flat with no cuts. It's just 1/16th. Less steps and tools, the better.200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:I'd be looking for an old angle shear.  It would be clean and quick.  One like a used WA Whitney would run around $4k working, unless that would be too much $$$.  - And of course I know where you can get those.Kris SikesControlled Automation, IncSales & Marketing Manager(501) 557-5109
Reply:Well? What did you get????200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:Sawz-all with the correct blade will rip right through those.  Pretty cheap way of cutting things apart.  Wear ear plugs  The Lord has declared, "This is my work and my glory--to bring to pass the immortality and eternal life of man"  Moses 1:39Link: My name is John, and I am a member of The Church of Jesus Christ of Latter-Day Saints.-- ColdCreekWorks.com --
Reply:Originally Posted by jdh239Sawz-all with the correct blade will rip right through those.  Pretty cheap way of cutting things apart.  Wear ear plugs
Reply:Originally Posted by denrepBiggest issue with the Dewalt saws was general rapid wear. Considering the severe service most of this was tolerable in a low-cost tool. However, what caused DeWalt's ultimate disqualification was the company's response to a battery retention issue. Any reciprocating saw can vibrate during extreme work; however, the Dewalt's plastic battery retention tabs tend to release the saw's heavy battery when the saw is shaken or jarred. Of course an unintentionally released battery usually plunges to its demise.  More so than the battery clip problem, what lead to the disqualification was the company's and field rep's indifference and practically denials when approached about such failures.Good Luck
Reply:I would go with the cutting torch if possible.
Reply:I think he's run from us?!? Things didn't even get ugly like usual! 200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.