Cutting Metal 101 (for n00bs)

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Hello.  I am new to welding, and for that matter I am new to working with metal.  I just picked up a MM180.I own an angle grinder with a cutting disc, and I have a metal blade for my miter saw.What other cutting tools would a small DIY'er need in his shop?  I must admit that I am not sure how to make long, straight cuts -- should I pickup a band saw?  Is the HF one crap for light home use?Feel free to point me toward FAQs for n00bs.  Thank you.
Reply:Tempo, what do you plan to build mostly?The first thing I would get is a metal cutting chop saw with abrasive blades.For heavy steel plate a O/A torch or plasma.  As far as the HF band saw I have one.  It works real nice.Be SafeLarryTry not use $10.00 worth of time on $.10 job!!Miller Bobcat
Reply:If the space is limited I'd go with a chopsaw.  They make a mess but are compact.DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Originally Posted by LarryMTempo, what do you plan to build mostly?
Reply:Originally Posted by TempoLet's assume space is not limited.  I am willing to pickup 1 or 2 tools that have a decent foot print.
Reply:For making long straight cuts on sheet metal:1st choice would be a shear2nd would be a plasma 3rd would be metal cutting "skill saw"4th would be an angle grinder (cut of wheel) with straight edge guide
Reply:You will need to do some thinking here as their are several trains of thought and opinions. budget will be the main factor as well. I prefer a bandsaw over chopsaw for several reasons. cleaner cuts, safer use, less Sparks and dirt are the big ones but a decent bandsaw will cost more then a decent chopsaw. If you can afford a decent bandsaw then I would get it over the chopsaw. I have the one I posted below and its a very good one for the price but a comparable chopsaw will only cost around 200.00 dollars. You will need to decide. I wouldn't use a chopsaw blade in a mitersaw, they are not designed for it. After that it on to a plasma or O/A kit depending again on cost and application. Hope this helpshttp://www.harborfreight.com/cpi/cta...emnumber=93507Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:There is no real equivelent to cutting wood on a table saw that translates to metal directly.  The closest you will get is a verticle band saw, similar to the onse used for wood, but the onse for metal go slower and have a larger capacity, and use wider heavier blades for metal.That being said, there are a million ways to skin this cat.  If you have an air compressor i think a nibbler should be your first choice.  I use these often and most have a capacity up to 16 gauge steel ( shears will do good too, i just like nibblers better).  You can get a cheap pair at harbor freights for only 25$ and they will last long if you take care of it with moderate use.  For stuff thicker than this i use a O/A torch set, but these can get expensive, a jig saw with a metal blade i've heard work well too, just a little slower going and they have real trouble with stuff thicker than 1/8 inch.  For just a hobby welder, i would suggest you get really good at using your anlge grinder and a cutting wheel.  You can do alot with that, until you narrow down your search for what you realy NEED.Good luck and have fun creating!
Reply:I like an abrasive cutoff disk in a circular saw for larger plate, and use a Bosch jigsaw on softer metals.  The jigsaw really sprays hot chunks of metal everywhere, including under my safety glasses Friday night - lucky it just got on my eyeball and not in it - gotta use the face shield.  I also like my tinted face shield for the UV (from sparks) and debris that comes with the abrasive disks.
Reply:You mentioned cutting a sheet of diamondplate, which is usually aluminum. For cutting aluminum sheet, the equivalent of a tablesaw is, well, a tablesaw. I've cut alot of aluminum on my wood tablesaw with a carbide tipped blade, it works very well. You have to be careful of kickbacks, but I've cut up to 1/4" aluminum.Miller EconotigCutmaster 38Yes ma'am, that IS a screwdriver in my pocket!
Reply:Originally Posted by TempoAt the moment steel is the only thing I can weld.  Someday I hope to be capable with aluminum.  0.25" is about as thick as I envision going with either.My first project is very simple -- a shelving unit with 1x1 square and 1" angle.  In the future I'd like to make a table and other stuff with perhaps 2x2 square. BandsawI'd like to make a toolbox, and it's not clear to me how to cut, say, a sheet of diamond plate (not even sure I am using the right terms here, sorry). Several ways here, Mini grinder with zip disks, Plasma, or  O/A, What would be the equivalent of using a table saw to rip a sheet of plywood?  How do I make rip cuts? Same as above or try the table saw idea mentioned in the previous postLet's assume space is not limited.  I am willing to pickup 1 or 2 tools that have a decent foot print.
Reply:Great info, thank you all for taking the time to respond. Originally Posted by jamlitI wouldn't use a chopsaw blade in a mitersaw, they are not designed for it.
Reply:Originally Posted by TempoMy next n00b question is this:  Do you cut metal with any oil or lubricants?
Reply:The horizontal band saws are nice, and worth every penny but rather slow.I recantaly got to play with all of the new Lenox steel cutting saw blades.  WOWMuch better than I expected.  Forget about that abrasive cut off blade, thease kick ***!  Ya they are more $$ up front but over the life if the blade are 1/2 the price of abrasives (according to the rep.  ).http://www.lenoxsaw.com/circsaw.htmGet one!
Reply:Cutting disks work for straight cuts on thin material 1/8" and thinner.  Scribe and make an initial grove carefully along the line and go back and forth until you are most of the way through then go back and cut through.For anything else a plasma, oxy-acetylene, air-arc, bandsaw, works better.
Reply:Read this thread I found it very helpful when I wanted to figure out what would be best for me to get to cut metal, a 'chop saw' or a band saw now I'm off to go get one.   http://www.weldingweb.com/vbb/showthread.php?t=12133This is the thread that led me to the above discussion, also some good info:http://www.weldingweb.com/vbb/showthread.php?t=12279
Reply:A cold cut saw (similar to a regular chop saw) with a carbide blade does a much better job than an abrasive chop saw.I have a Milwaukee 8" Metal Cut saw for cutting plate (looks like a skil saw and uses a carbide, metal cutting blade).  It cuts 1/4" steel plate like a skil saw cuts 1/2" plywood.  If $ are a big factor, a cheap skil saw with a 7" Bullet blade will do a good job on steel up to 1/4".  Blade just doesn't last as long.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:Depending on what you do most and much ou do it, you could always contract out cutting.  Spend more time building and less time preping.For plate you order it close to what you want and use a torch o/a,o/p or plasma.  I prefer bandsaw to chopsaw.  Bandsaw is slower for individual cuts, however. It is quieter and less mess, though.
Reply:I can handle most of my cutting needs between a 4.5" gridner  and a hacksaw (my time is cheap so a little patience can save me a lot of money in "convenience tools").  On top of the grinder and hacksaw, a really nice pair of shears is a must when sheet metal is involved.
Reply:I have not read it in any response, maybe I missed it. What is it? IT would be the backup that never backs down, Sawzall. I've used abrasive blades in my worm drive Skilsaw to rip metal. A torch would be way easier though! City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:Ya, those squirrels work for me in my shop.  Great bunch of guys.  They work for almonds and they get a cashew bonus at the end of the month.
Reply:Originally Posted by WelderBoyYa, those squirrels work for me in my shop.  Great bunch of guys.  They work for almonds and they get a cashew bonus at the end of the month.
Reply:Does HF carry squirrels...? I'll have to check their flyers.
Reply:Why question is why not build a cold saw? I will build one soon once parts are available to me. I have the worm gear being shipped as we speak=)
Reply:Originally Posted by azlarDoes HF carry squirrels...? I'll have to check their flyers.Clamp a straight edge to your work, run a jigsaw with a metal blade along it. Works for sheet and plate. A sawzall is great for channel, tube, and pipe. Use a vice or clamp to hold your work to a STURDY table. You only need to be 2% smarter than what you are working on.Lincoln pm140hacksawa big hammer
Reply:I have been using a sawzall, chopsaw, and an angle grinder for a while now. I just bought a plasma so its going to make my life easier. Sawzall blades are expensive and you can run through them pretty quick, not to mention they bend pretty easy.
Reply:I don't have one single cutting device that doesn't get used at least on occassion. You can't have too many.  Some, like the sawsall are very rarely used, but when it is it's because nothing else will do the job quite as well.
Reply:I bought a 140 dollar portaband saw from grizzly.  The table that came with it is junk, but the saw cuts well.  I built a jig for it from some scrap metal and now I have a compact benchtop vertical bandsaw.  It is awesome.  It will cope angle iron very nicely, make square cuts on tubing.  I am so glad I didn't spend the money on a chop saw because this baby will do so much more than turn one piece of metal into two.
Reply:Originally Posted by azlarDoes HF carry squirrels...? I'll have to check their flyers.
Reply:Cutting metal with your miter saw will really shorten it's life span. Get a good chop saw for that type work. Most brands run around $200. I've used all the major brands at one time or another and they are all pretty equal. I use a Rigid in my shop, but it's handle design was more of a factor in my choice than anything else (I have a bum wrist so things like that get thrown into the equation).The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Originally Posted by Me!The horizontal band saws are nice, and worth every penny but rather slow.I recantaly got to play with all of the new Lenox steel cutting saw blades.  WOWMuch better than I expected.  Forget about that abrasive cut off blade, thease kick ***!  Ya they are more $$ up front but over the life if the blade are 1/2 the price of abrasives (according to the rep.  ).http://www.lenoxsaw.com/circsaw.htmGet one!
Reply:Newby here with a question.Sorry if this is not the place to post this question, but I will ask anyway.Can you guys exlain what the differince is between hot and cold rolled steel, and which can be used in a compact bender. I want to do some small projects(ie. wine racks ect...ect ...)Tkanhs for any help.
Reply:http://www.spaco.org/hrvscr.htmHeaps of info here (With out the myths   )A good guess is better than a bad measurement
Reply:A 14" wood cutting vertical bandsaw can be had for very cheap and slowed down to cut metal via jackshaft or treadmill motor. In my opinion a vertical bandsaw is a really flexible machine, and you can get into a good setup for really cheap with a little ingenuity. Wife bought me a 3/4" 14" vertical wood bandsaw for my birthday.$35 for an old treadmill a 2 hours of work and I have an essentially infinitely variable speed 14" bandsaw with a 1.5hp DC drive on it.