Need to cut 200 1/2" Bars

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I need to cut 200 peices of 1/2" bar stock for a fence that I am making.For the last fence I did I made the cuts with a Milwakee portable band saw with stand.  It did an okay job but was not that fast.   I also have a metal chop saw but that is so loud and would take a while too.I have a place down the road that I can rent a plasma cutter for a week for $100.  I rented it from them last week to cut some angle iron at an angle that kept it from fitting in the chop saw.  I loved it but my lines were only so so as far as being straight.Is there an inexpense jig that I could buy or build for the plasma that would help me here?Also, does anyone know how good the ground needs to be?  I was wondering if I laid 10 peices of 1/2 bar flat on a table (touching tight to each other) and then clamped a peice of flat stock accross them could I ground to that and cut the 10 bars in one shot without having to ground them all individually?   If I need to ground them one at a time I might as well use the chop saw. I think what I really want to do is figiure I way to do it with the plasma cutter and then convince myself I should just buy one..
Reply:I would do as you describe with the table and clamp the work wire directly to the table, then cut.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:If you set them on a metal table you can ground to the table.  As far as a jig a piece of angle iron set back from cut line will do the trick.  You may be able to hold it with a couple of welders magnets.  A test cut will let you measure the set back for the angle.As far as plasma you will need a Cutmaster 52 or equivilent for a quality cut on half inch.DennisThermal Arc 185-TSWMillermatic Challenger 172VictorO/AAtlas Craftsman 12 by 24 LatheEsab PCM-875Wholesalem Tool Mill-Drill
Reply:Thanks for pointing that out Tailshaft - I forgot to mention the table should be metal but I figured he would hopefully already be using one. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Plasma is probably overkill for 200 bars. Took about 3 hours to do more 3/4" rebar than that with a 4 1/2 grinder and cutoff wheels. Total cost: less than $10 for the cutoff wheels.
Reply:Harbor Freight makes a small holder that makes a 4 1/2 grinder into a miniature chop saw.  I think I paid $18 on one of their sale days.  That and a cheap $12 import grinder and a dozen cutoff wheels should do the job quickly.
Reply:4x6 bandsaw works great for this kind of stuff.  Set up a length stop, and have at it, chuck up a few at a time.  Helps to have something else going on in the shop so you aren't just sitting there staring at it while it cuts.
Reply:Sounds more like you need encouragement to buy the plasma cutter than that you need advice on setting up the cut.  OK.  Here it is.  Go for it! It will do the job fine and you will feel good about it during and after the job.  Bandsaws, chop saws, and angle grinders will do the job too, and much cheaper, but won't be nearly as much fun.  And after the task is done, you will have the plasma cutter.  Just remember, we are not handing out financial advice here.My only caution is that I would recommend laying a braided ground strap across your table under the row of bars and clamp a bar or 2X4 across the row of bars above the braid to be sure each bar has a good ground.  The clamping bar or 2X4 could act as your torch fence also.  I don't think that gravity alone will assure a good ground to all bars and it is really annoying to have your torch start spitting and arcing internally because you lost your ground in the middle of a cut.  Internal arcing is bad for the torch guts.awright
Reply:I'd bundle these things in rows of 4 high x 4 wide, weld one end of the bundle together so they'll stay together and run em thru the saw cutting 16 at a time. Chunk the "butt" end when you're done.
Reply:Chop saw is too loud?   Just get some ear protection and go at it.To speed things up, you could gang several pieces together and cut them all at once.  If you rig up a stop, you can do it quickly and accurately.Then again, if you just want to get a plasma cutter for the heck of it, go for it.
Reply:" RENT A HELPER"That's what I call it when I have someone else do my boring work. Instead of buying your material in full 20' bars, price it cut to size. It is generally inexpensive, guaranteed to be within 1/8", and come all bundled ready to assemble. I do this with all longer rail panels, and all home railings, (I keep a stock of ready cut 1/2" sq.)Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:If your purchasing the bar stock from a supplier then have them gang cut the material for you..... If they can't or having whoever you're buying your stcok from doesn't have the ability to do this then do as ronnielyons suggests except a few bucks and purchase a small band saw. If you've had to do this before you'll probably have to do it again..... eventually you make back the investment cost.... you also wouldn't have had to rent the plasma cutter for those angles, there's a 100 toward the saw, and your cuts would have been exact.http://www.epinions.com/hmgd-Shop_To...ndsaw_HVBS_7MWhttp://www.epinions.com/hmgd-Shop_To...ndsaw_HVBS_463I have one like the first one and it has been a great tool._________________Chris