Metal cutting tools recommendation?

[rbstern]

I'm getting a bit more into welding. Mostly light duty stuff so far, done with inexpensive wire fed MIG and arc welders.

Any cutting and fitting I've done so far has been with a Harbor Freight 4 1/2" angle grinder using a cutoff wheel. It works well for the rough cutting I've been doing. For example, yesterday I welded a small tab made from 3/16" flat stock, on a broken 22 rimfire spring actuated/knockdown target reset paddle. Exact fit was not important. I just needed a 3/4" x 3/4" piece from a piece of flat stock, roughly in the shape of a square. Cut it with the angle grinder.

I suspect I will get to projects where I want to fabricate mounts or fixtures out of 1/8th, 3/16", or 1/4" mild steel, where a close fit between two parts is needed.

Is there a decent, one tool cutting solution for a casual/occasional welder?

Also, could use a recommendation for good sources of scrap metal that any good scrounger would be adept at finding. Tube, flat, angle, etc. I'm sure, with more experience, I'll come to "see" perfectly good scrap metal about to be discarded, but my eyes/brain aren't trained for that. I "see it" with wood, but not yet with metal.

 

[AWSubie]

I use a porta band for cutting smaller pieces of metal. I can’t imagine being without it. Works great and is also a good beginner project for you to make a stand as well as a small table rest.

A tool I wish I had is a metal chopsaw. (Not the abrasive type, I have that) but had I known in the beginning I would’ve bought the metal blade chopsaw.

 

[bigtiller]

Is there a decent, one tool cutting solution for a casual/occasional welder?

The short answer is no.
I used an abrasive cut 14" saw for many years and was happy. And then I bought a dry cut saw. I use it most of the time and seldom ever use the abrasive saw anymore. There are times when a band saw would be handy and a plasma cutter, but remember, it's just a hobby.

You also need at least 4 angle grinders and 2 die grinders so you don't spend a lot of time doing change-overs.

I have a dry cut saw made by Fein with German engineering, it came square and plum, right out of the box.

FEIN-729 | Acme Tools

 

[metalbender]

+1 on the deep cut porta-band. Have most of the required metal cutting tools. Stationary band, abrasive chop, 12 inch shear, electric and air shears, angle grinders, plasma and the deep cut porta-band. Next to the plasma, the porta-band is among the most versatile. Had the Chicago electric version, worked well untill some heavy cutting, then it let out a bunch of the magic Chinese smoke, upgraded to a Milwaukee model. Still made offshore, but with better QC.

 

[Big Barn]

You are already familiar with using a cut off wheel in your angle grinder. If you are using a traditional thin bonded abrasive wheel I would recommend getting one of these instead:

Lenox 1972921 4-1/2" Diamond Cut-Off Wheel - KMS Tools

I’ve been using this one for almost a year. I’m certain I would have gone through at least twenty abrasive discs by now. I find it is way easier to control with greater precision. And no wasted time with blade changes or loss of cutting diameter.

Also safer as they are less likely to explode than questionable quality abrasives.

 

[metalbender]

Been using the Makita thin abrasive discs, that Lennox is looking good at the price, even in Canuckland. Thanks

 

[TractorGuy]

I may have to try a diamond cutoff wheel when I run out of abraisive discs.

My cheap bandsaw died again this year and I replaced it with a Cut50F plasma cutter. I like it so far but takes a while to set it up and start cutting. I am using my generator to run it. Cuts are nowhere as clean and precise as a bandsaw.

I almost bought the small HF bandsaw which is similar to the saw I had. It can be used in the vertical or horizontal position and was very handy when it worked. It would try my patience at times.

 

[Big Barn]

metalbender I think you’ll be quite pleased with the Lennox.

I really should order a 4” one for my extended reach cut off tool but I still have three boxes of 3 and 4 inch abrasive discs.

To the OP. Another great tool is the extended reach cutoff tool. I wouldn’t put it on your priority list as what others have mentioned well do you well. But it is an awesome tool.

 

[Mowens]

I have the 4.5 angle grinder, and a HF bandsaw that does 4x6 vertical and horizontal. I honestly use the crap out of that bandsaw. I dread pulling the grinder out.

 

[Dneel81]

OK ill be the jerk and mention a plasma cutter. They're expensive but so efficient. They do require the big plug but they're so fast. I learned on the grinder with the lenox wheels and then borrowed an oxy/acet torch. Plasma is so quick and nice. I've built several tractor implements, tools, bumpers for my tahoe, etc. it'll sever 1" if you go slow enough but I can get through 1/4" so easily. I bought a hypertherm45. As always buy more than you think you'll need.

 

[downsizingnow48]

The thing about metal working is you will often find you need another tool to do what you really want to do.

For your next tool up from the angle grinder I would also think of a bandsaw or a dry cut chop saw.

Not mentioned yet but an extremely useful item is some kind of belt sander / belt grinder. For deburring, softening edges, putting a radius on corners, tidying up a ragged O/A or plasma cut, many things. You can spend a lot on dedicated belt grinders, but for years I made do with an upside down Bosch handheld belt sander in a DIY frame with a ceramic belt either 60 or 120 grit depending.

 

[grsthegreat]

I love my plasma cutter. Its about 8-10 years old and I still use it for many projects. I had to cut some 12g into a 24 diameter circle with a 2 center cut hole for my 3 point fence wire unrolled. Only took a few minutes to manufacture... mind you I have a plasma table so I cheat a bit.

 

[Seven Gables]

I like to use my stationary Ramco metal cutting bandsaw on the big stuff., think it handles up to 12-13" horizontally. Milwaukee deep cut for smaller stuff, very handy. 41/2" angle grinder and even a quality air die grinder with abrasive wheel for cutting and grinding smaller items. One thing that I can't emphasize enough if your new to the metal working game is always always wear a set of eye goggles when using a grinding wheel. There is just about nothing more miserable than a a tiny metal flake or even the metal dust in your eyes. Ask me how I know. PS big Barn that Lenox wheel looks like something I need to try, thanks for the tip. B

 

[ArlyA]

For one, I'd suggest a cordless bandsaw. Like this one by Makita. Gee whiz are they handy.

https://www.amazon.com/Makita-XBP02...less+bandsaw&qid=1559004779&s=gateway&sr=8-10

Any cutting and fitting I've done so far has been with a Harbor Freight 4 1/2" angle grinder using a cutoff wheel. It works well for the rough cutting I've been doing. For example, yesterday I welded a small tab made from 3/16" flat stock, on a broken 22 rimfire spring actuated/knockdown target reset paddle. Exact fit was not important. I just needed a 3/4" x 3/4" piece from a piece of flat stock, roughly in the shape of a square. Cut it with the angle grinder.

I suspect I will get to projects where I want to fabricate mounts or fixtures out of 1/8th, 3/16", or 1/4" mild steel, where a close fit between two parts is needed.

Is there a decent, one tool cutting solution for a casual/occasional welder?

 

[chim]

DeWalt 20V cordless tools have a special place in my heart. Jig Saw does well up to about 16ga. Recip saw does bigger stuff. Grinder with Harbor Freight cutoff wheels works well and is especially handy for cutting stuff in place. Band saw makes short work of pipes, channels and square tube.

Cord-connected tools are a Harbor Freight 6X4 horizontal band saw, the old recip saw and just last year I added a Hypertherm Air 30 plasma cutter. The Air 30 cuts everything I get into, plus it has its own air and and can be used on thinner material with 120V power.

 

[Smokeydog]

For one, I'd suggest a cordless bandsaw. Like this one by Makita. Gee whiz are they handy.

https://www.amazon.com/Makita-XBP02...less+bandsaw&qid=1559004779&s=gateway&sr=8-10

Bandsaws any size are helpful. Multitool belt grinder is on of the most used tools in the shop.

 

[spitter]

If you don't want to spend much money a angle grinder with a zip wheel is pretty much all you need . Not the best at anything but there is nothing you cant cut with it. When were on a job and don't have the rite tool we just grab a angle grinder and a zip wheel. Next cheapest is a chop saw and a abrasive blade cut metal studs with it for years. Cuts everything not perfect but for $150 dollars and blades are like $5.00 a piece it can't be beat.:drink:

 

[lennyzx11]

Yesterday I grabbed my DEWALT 20 v cordless 4 1/2” grinder with a thin cutoff wheel and used it on the garden gate to cut the protruding screws off.
A few days ago I used my cordless Milwaukee deep bandsaw(portaband) to cut a piece of 1/2” plate steel. And some 2” square stock for a receiver gadget for my box blade.
Then an old corded craftsman 4” angle grinder with a wire wheel cup has cleaned stuff up for at least 25 years for me that I can remember.
Another corded DEWALT angle grinder has flap disks on it which I never knew about until reading about on here. Best thing since Butter!
Then the Hypertherm Air30 plasma cutter for some aluminum thin metal for a patch was used last week.
I’ve wanted a chop saw for years but can’t justify one with all I have now that does the jobs I need done.
That DEWALT cordless angle grinder with a thin cutoff wheel sure makes life nice for stubborn bolts and quick cuts around here though. I’m not even sure where my hacksaws are right this minute.
Lenny

 

[TractorGuy]

Don't rule out a cordless reciprical saw. I find myself using that more and more for the cuts I used to use my bandsaw for. Get your piece level in the vise and you can get pretty straight cuts with them. I recently tried some HF metal cutting blades and found them to be pretty good.

I did like my 4x6 bandsaw but it took up more space than the HF welding cart and plasma cutter. The plasma cutter is more portable and makes short work out of long cuts. I recently sliced one side off a piece of 4" angle that was 5' long in about 2 minutes or less. Try THAT with a bandsaw.

 

[yomax4]

At some point many hobby guys will likely aquire all of the above. I couldn't imagine not having a dry cut saw ( or 2 ) a few angle grinders with various wheels, Plasma and Oxy-fuel, Band saw, shear and nibbler. Enjoy.