Best way to cut expanded metal?

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Ok, i'm sure the "best" way would be using a plasma cutter, unfortunately i don't have one. I think if i use a torch it would melt back too much so i'm left with a cuttoff wheel or bandsaw right?  The material is 13g 1/2" hole expanded mild steel. I have to cut a table top out of it and its a weird shape.  kinda like a square egg shape if that makes sense.
Reply:Cut off wheel.  Or, and I have never tried it, you might be able to do 13ga with side cutters.
Reply:Good thing you don't have a plasma, works like crap on that. stop go   stop  go.. If you don't have a shear.  then  torch or wiz wheel. When doing weird shapes, I like the wiz wheel with small blades. Just don't forget to de bur your cuts!Lincoln Ranger 8                        Lincoln 175                          Drill pressLincoln 225 mig                            Plasma                              8 ft brake        52" jump shear
Reply:Thanks for the info, cutoff wheel it is.
Reply:I concur on the plasma.  It would be my last choice for cutting expanded metal.  The torch works well on thicker stuff, but IMO the cutoff wheel is best on the thin stuff, either in an angle grinder or a circular saw.  Just thought I'd kick the dead horse a bit. Work HARDER, not smarter! ------------------------ Miller Bobcat 250Millermatic 251Lincoln Precision TIG 185Hypertherm PM 600Hobart 135 HandlerOxweld 400 FlameMaster
Reply:I've even cut quite a bit up to about 1/8th using smaller bolt cutters. What is 1/8th, about 9 awg.? Just mark it out and plan your cuts. You end up with some sharp points you need to flap smooth.Doing an egg shape you'd have to plan your cuts. Thinking and planning go with any job.
Reply:Yes, planning is always critical. I have already cut out a clean template on thin paper board. I'll just place the template on top of the expanded sheet and have at it with the c-o wheel.  I will leave a little extra and grind it to fit.
Reply:Used properly, a torch is one of the best methods. Quicker, cleaner, odd shapes no problem, sharp corners, no problem....no burrs, not much clean-up, it is mostly blown away...
Reply:Originally Posted by 7A749After kicking that dead horse, you could cut it up with a cutoff wheel too.......
Reply:Well a plasma cutter will work as long as the plasma torch has a pilot arc to carry it over from grid to grid on the expanded metal.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:13 ga shouldn't be a problem w/ a torch. Use a good clean 000 tip and lean it over @ 45* angle away from the cut direction.                        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:Hey, I think I just heard the horse nay Barring plasma, I'd cast my vote for abrasive slicing wheels.However, I'm surprised to hear so many nay sayers to plasma.I thought cutting expanded was one of plasma's fortes; I've always had good results with it.Here's a recent plasma cut:Attachment 37836This was a rough cut so that the piece could be slipped over a shaft, to then have it's final shape traced out.Just lay a guide down, and zip, it's done.Good LuckLast edited by denrep; 10-19-2010 at 11:42 PM.
Reply:I like a jig saw.
Reply:milwaklkee  metal saw.   I think they run about  3 bills. HF for 100 or so.
Reply:We cut 4x8 sheets all the time. 7 1/4" fiber blade on a skil saw. Fast and straight. I've done plenty with a cutoff wheel but it took longer and was harder to control.9er
Reply:I haven't heard anyone mention sharks with freakin' laser beams attached to their  freakin heads...   Attached ImagesWork HARDER, not smarter! ------------------------ Miller Bobcat 250Millermatic 251Lincoln Precision TIG 185Hypertherm PM 600Hobart 135 HandlerOxweld 400 FlameMaster
Reply:A hydrojet would be best but im guessing that is out of the budget
Reply:Easwy way Attached ImagesA butterfly without wings, is just an ugly bug
Reply:just use a 3/32 6011 rod @ 180 amps. those rods have a lot of arc force.
Reply:Thanks for all the suggestions. I ended up cutting it with a C-O wheel and used the torch for the curved stuff.
Reply:Originally Posted by Leadhead1911I concur on the plasma.  It would be my last choice for cutting expanded metal.  The torch works well on thicker stuff, but IMO the cutoff wheel is best on the thin stuff, either in an angle grinder or a circular saw.  Just thought I'd kick the dead horse a bit.
Reply:denrep,that is a mighty wide kerf.Last edited by Scott Young; 08-21-2009 at 09:13 AM.
Reply:Originally Posted by weldbeadi want to ask about what is the best boots towear for kicking a dead horse.. should that be a seperate thread?
Reply:These boots would probably work... Attached ImagesWork HARDER, not smarter! ------------------------ Miller Bobcat 250Millermatic 251Lincoln Precision TIG 185Hypertherm PM 600Hobart 135 HandlerOxweld 400 FlameMaster
Reply:Well she might cut the mustard with those but expanded metalCo-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.Originally Posted by specterWell she might cut the mustard with those but expanded metal
Reply:Check out the video on Longevity part of this web site.   A video showing a new plasma cutter that si the closest to an A/O torch that I have seen.keith The older the boys, the more expensive the TOYS!!Previous owned;Linde 300 Amp welderMiller Gas drv welder, Tumbstone,Dayton Miller ac to dc converter,High frequency unitLongevity LS60PCurrrently owned;Longevity WeldAll 200PI
Reply:Originally Posted by KHKCheck out the video on Longevity part of this web site.   A video showing a new plasma cutter that si the closest to an A/O torch that I have seen.
Reply:I'll stick with my Hypertherm Powermax 45 for cutting expanded steel! It has a much finer kerf on its cut.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Well there's plasma, and then there's plasma . . .I've seen this thing cut perfect circles out of catwalk material.  Expanded metal would be nothin'.  Just need to find someone that's got one.More info at www.pythonx.com
Reply:Watch that pyhonx video and check the name on the plasma head.If you cannot convince them, confuse them.         Harry S Truman
Reply:If you have a hand held plasma, the plasma might cutout, depending on how fast you are going. It can be a pain, because, you keep starting again and again. It takes a fraction of a second to start.You could use a cutting torch as well. Up against a straight edge. But you would have to clean up the dinky berries. I use a shear or nibble myself. On a shear, you just cut a little notch on the line you want to cut, bend down a tab on the drop off. Push the piece into the shear, pull it back until the tab hits the bottom blade, and then cut it. If I use a nibbler, I just ride it along a straight edge. You might be able to set a metal cutting carbide blade, to almost cut through it. Then just bend it back and forth once or twice. Clean it up with an angle grinder. You could also cut it with a saber saw, or reciprocating saw as well. A bit slow but it would make a nice cut too. You could setup a heavy steel straight edge, on the top of the metal, using large "C" clamp, and run a sawsall down along the straight edge. You might need two guys though. Again you would probably get a nice cut.        Sincerely,             William McCormick
Reply:If you have some scrap metal around, you may also be able to lay a piece of 20 gauge, scrap metal over the perforated metal, and cut right through both pieces, using a metal cutting carbide blade.A Beverly shear although not designed for that would probably cut It very nicely. A pair of bulldogs also not designed for that, might do it too.       Sincerely,             William McCormick
Reply:But the very thin 1/8' thick, 4.5 inch diameter right angle grinder, cutoff wheels would cut that nicely too. You might need four or five of them to cut up a four by eight sheet, it depends upon the wheel.        Sincerely,             William McCormick
Reply:All of my plasmas have a setting for exspanded metal.   If i have to trim some in the field i use a parting tool on a small 4.5" angle grinderVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Yes a plasma works very well for cutting expanded metal. I have also used a gas powered cutoff saw that works very well also. Just put a piece of flat or angle iron down on your marks and follow it with the cutoff saw....works great especially in the field. 6"XX P5P8 6G
Reply:I have also used a gas powered cutoff saw that works very well alsoDevis mutuelle familiale de France | Comparatif la mutuelle familiale fr | Mutuelle familiale de France
Reply:Poor horse You fellas gonna have the animal rights activist all over ya!Don't let that iron in your lungs, turn to lead in your @$$!!!!
Reply:I liked the sharks with frigging laser beams myself.        Sincerely,             William McCormick
Reply:The VERY best way to cut expanded metal -  especially very heavy expanded metal  -  with plasma is this puppy:Get more info at their web site:  Plasma for Structural Steel Fabrication
Reply:Plasma does do a nice job on expanded metal....if you have a plasma that was designed for fast transition from pilot to cutting arc, and then back to pilot arc. When satelite dishes (remember the big mesh ones?) were made from this material there was a big demand for plasma on automated machines or robots for cutting expanded metal.The picture of the robotic Python is of a Hypertherm HPR400XD.....it actually cannot cut expanded metal.....but it can cut with a thinner kerf than a Powermax30 (when operating at 30 Amps on gauge material).....and can also pierce 2" steel and cut it at 30 inches per minute. 1/2" steel can be cut at 185 inches per minute.....consumable life can be measured in miles of plate cut....and typically over 3000 starts....depending on what you are cutting...of course.Jim
Reply:the new miller 625 and 825 will cut expanded metal
Reply:I got this 7 1/2 inch blade that rocks. It cuts up to 1/4in steel and cuts through angle like butter. really just put in on a circular saw and go to town. I was amazed by what it did. I got mine cheap on amazon.com for 40bucks you cant beat that. I have make lots of cuts with my blade and hasnt let me down. http://www.metaldevil.com/