Header Collector cutting w/ dry Cut Saw

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OK so I decided to chop up some more collector pieces tonight,. I have seen some insanely over-complicated solutions for this.  I more-or-less want to have sex with this dry cut saw every time i touch it, but the concept should work for a regularabrasive saw. Also I sound extra hilariously Canadian on video, it's like Bob and Doug Mackenzie teaching fabricating...  This was pretty fun to do- and WAY more helpful/interesting than some pics I think. I need to clear off the memory card so i can do some other demos. Enjoy!Edit: can we embed videos here? my embed code didn't work, link is here:http://i289.photobucket.com/player.s...b/MOV01398.flv
Reply:Yup! It makes excellent, acute angle cuts. That's good.You may want to consider using steel flat, etc.--for good blocking to clamp on thosetube ends--with lots of end support--rather than the round punch. That round punch can roll (the light duty vise of that saw wants to push uP when tightening), shifting the tubes and the result can be painful.Blackbird
Reply:The punch is hex shaped actually where it's holding the material, but ya I can see the part sticking out make it look round! Something round would not be healthy for sure. A fixture would be much better as I mentioned that in the video.  Really though the amount of surface area you are actually grabbing on that end of the piece is quite small. The fixture would help more for repeatability's sake than anything. The important things are that everything is SQUARE and the vise is TIGHT. The vise is easily heavy enough to do the job, BTW. The surface finish and straightness is a fairly good indicator of a fairly stiff setup IMO. With hard material like stianless, if it can chatte ror vibrate, it will.People underestimate these saws and have problems with them that are primarily due to operator errror, and are not the saw's fault. Cheers!Last edited by Capnbondo; 09-17-2008 at 02:05 AM.
Reply:Originally Posted by Capnbondo I more-or-less want to have sex with this dry cut saw every time i touch it
Reply:Thanks for posting that video - I've been wanting to see a dry cut saw in operation.  I do almost everything with a cold saw, but occasionally have to use the abrasive chop saw on angles such as shown in your video.   And you're right - you sound Canadian through the whole video! Jason
Reply:Cheers guys,If blade life ends up being really terrible with this thing, I might actually look into a cold saw. These cuts are pretty much one of the worst scenarios imaginable than one could subject the blade to, so I guess I'll just have to see. Honestly it's so fast even if I only get 200 cuts between sharpenings it's still worth it. I really would prefer to avoid a cold saw though, as I like avoiding coolant when I can. It's nice to not have to wash the parts, and I can clean up the work area with a dust buster, as opposed to having to deal with coolant-soaked nasties.
Reply:A cold saw might not be as bad as you think, it didnt make the area around it any dirtier than a dry cut would and washing off the coolant is as simple as dipping it into a 5 gallon bucket of water. Plus you dont have to wait for the part to cool down.Have we all gone mad?
Reply:Originally Posted by sn0border88A cold saw might not be as bad as you think, it didnt make the area around it any dirtier than a dry cut would and washing off the coolant is as simple as dipping it into a 5 gallon bucket of water. Plus you dont have to wait for the part to cool down.
Reply:I have to agree with Capnbondo, my dry cut saw is one of the best buys I have made. If you don't get carried away with downward pressure the blades will last for hundreds of cuts. My 2nd blade is going strong after learning the pressure lesson on the first. I have used a wet saw also but I'm not sure I would trade for one right now.JimCut an MGB and widened 11" C4 Corvette suspension and LT1 Chevrolet power & 6 spd. Pictures here:Part 1http://forum.britishv8.org/read.php?13,7581Part 2http://forum.britishv8.org/read.php?13,22422
Reply:I cant' watch videos%$&*^#@ DIAL UP"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Capn - Great post . What type of blade are you using in your demo?
Reply:Originally Posted by CapnbondoDid you watch the vid? I picked the part up with my bare hand right away. They don't get very hot at all. If the part is getting hot, you're doing it wrong. Honestly it's working really well at this point, I won't be spending 2K on a cold saw unless SERIOUS issues arise with respect to blade life. I am really happy with the results.
Reply:Sn0border,In my opinion, it is a safe rule of thumb that if you are saw cutting anything, it should not be gettting very hot. If is getting so hot that you actually need to wait, or dunk it in water before you can reasonably handle it, you are overheating the cutting tool and most likely decreasing the lifespan of the cutter significantly with every cut. This goes for pretty much any sawing process, be it a carbide cutter or HSS or bitmetal bandsaw blade or etc.  Exotherm,Thanks! The blade is an interesting one. It is an 80 tooth, made by CMT which is an italian company that makes basically nothing but cutting tools, and seem to be very R&D oriented and high tech. I really bought it because they claimed it was ok for stainless use (a LOT of manufacturers say their blades are for mild steel only- IE Freud Diablo) and at $120 it was by far the cheapest option that actually claimed to be capable of cutting stainless. (Makita's stainless blade is more like $180, although I bet it is a badass, the standard 60T that came with the saw is quite good).Being an 80 tooth blade, it is pretty fine, I switch to the original makita 60 tooth for cutting anything thicker than 1/4".  So far so good.
Reply:Cool. Thanks for the info.
Reply:Great demonstration.  How do you go about figuring the angles out for the collectors?  It looked like you had some nice looking collectors already built in the background in the video.
Reply:If you go to Homemadeturbo.com, in the welding section, you can find how-to's on collector cutting.
Reply:Originally Posted by CapnbondoI more-or-less want to have sex with this dry cut saw every time i touch it...