Cutting metal - the options.

B

blindrobert

Joined
Jan 15, 2014
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Let me start by saying I'm new to knifemaking.

I'm looking for a way to cut metal and my options seem to be porta-saw with Swag table, full-size metal band saw, torch. I don't have either of these things it seems like the porta-saw from DeWalt or Milwaukee with the Swag table will cost about the same as a 4x6 floor-standing band saw from Grizzly. The torch is tempting (taking a welding class this weekend!) but seems like it could cause problems overheating the steel in the roughing stage.

Recommendations? I'm leaning towards the porta-saw, just because it will store away on a shelf and not take up valuable floor space in my shop. There's probably a torch in my future, but seems like it's not necessarily the best tool for this.

If it influences your thoughts, I'll be doing the grinding/refining on a 2x72 belt grinder.
 
I have a DeWalt porta-band saw with a Swag off-road adapter plate. I use it quite a bit but, I have other options in my shop for cutting steel as well. The one thing I do not like about using the Swag plate is the six inches of open blade. If your hand slips into the blade, it is going to be bad! Some enterprising person should come up with an adjustable blade guard for this setup. I bought a cheap foot switch from Harbor Freight to turn mine on and off which worked out well since the switch in the saw broke in the on position shortly after I got the foot switch. Also, I only bought the mounting plate. He sells a leg set to go with it but, I just clamp the lip of the plate in my bench vise.

Bob
 
Thanks for the tip, RBTX! The only reason I'm debating the issue at all is that the porta with table costs about the same as a floor bandsaw (lower end, but fine for my purposes).
 
Forget about the torch. How about using a high-tension hacksaw or an angle grinder? Either will do a good job, be much cheaper and take up less space than the bandsaw options.
 
Hacksaw. I bought an angle grinder the other day for this job, but I've not used it for roughing blanks and probably won't. Not after some reading, but let's not turn this into that thread. :)

For me, the high tension hacksaw with 24tpi bi-metal blade works pretty good. Feel that muscle burn! :p
 
Yeah - I have a hacksaw and good blades - maybe that's the best way to go until I get a few knives under my belt. I just hate doing things in a way that takes too long. Have an angle grinder too but don't like it for other than simple cutoff operations.
 
I use an angle grinder for most all of my blades. It would be a real pain to maneuver a 6 inch wide x 36" long chunk of steel through a bandsaw for me, so the angle grinder with HF cutoff discs works great for my purposes. I am aware that there are potential safety issues, but I think they're way overblown in this forum. Angle grinders get used on a regular basis for cutting things up, of all different varieties. In fact, that's one of the purposes for which they were designed. As with any other power tools, if you're dumb or careless, they can hurt you. The same is true of a bandsaw though. An angle grinder will run you 30 bucks, and cutoff discs are pretty cheap. I tend to use 2-3 for a big long blade, and 2 will generally net me at least a couple smaller blades. I do want to get a portaband and swag table at some point, but not until I have a shop big enough for a bandsaw station with plenty of room on all sides to maneuver steel through the thing.
 
There's also the connect-the-dot method. I use a drill press to drill, then a combination of cut-off wheel and hacksaw to cut between the holes. This requires a good bit of clean up with files and grinder.
 
I built a stand for a Harbor Freight port-a-band for under $100 including the saw. Later I received a used Milwaukee from a relative who's a GC and so I bought a swag table and sold my HF to a buddy. I miss the HF. Aside from being real loud, I was able to cut stock lengthwise with no problem due to the blade being offset to the housing. Can't do that on the Milwaukee. Also, while the Swag table is nice it isn't as sturdy as the one I built and the whole thing is much bulkier. On the plus side I guess it's more versatile if I ever want to take the saw off the table. PM me if you want to go the HF route, or do a search. I think I did a sort of WIP on it.

Eta: http://www.bladeforums.com/forums/s...able-Band-Saw-Stand-WIP?highlight=Port-a-band
 
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I have Dewalt Portaband with a free standing Swag table. I use this little tool for a lot of different jobs beside a cutting steel. Today I'm cutting 23 blanks out of damascus. I almost never use my full size wood cutting bandsaw anymore, it's gathering. I use the Portaband for handle scales too. Hands down it has the most I don't know how I got by without it factor of any tool in the shop. Well maybe the 2x72 with VFD is right in there too.
 
I'll use the AG for simple cut-off from the bar stock, just not for roughing out. I like to think myself handy and safe with any tool, for that reason I'll want more experience before I decide on the grinders full potential. Luckily the bar stock I'm using atm doesn't require a lot of removal to cut up a reasonable blank. Just a few corners here and there and it's ready for the belt. Those corners take all of two minutes effort with the hack.

I like to think that the future holds a justification for a small shop bandsaw, but not now. Especially since there are big industrial oil cooled saws at work that I don't feel the need to exploit. If there is anything resembling priorities in my garage any real money should be thrown directly at a decent belt grinder, or materials. ;)
 
I use an angle grinder with cut off wheels (mainly cause a 14 year old can't afford a bandsaw). It is pretty quick work, I cut out 2 5 inch blade blanks in about 15 minutes. You might want to get a leather apron though. A cutoff wheel is only a couple of millimeters thick, and when it rotates at 3600 rpm, it can shatter pretty easily. I had a normal grinding wheel blow up on me last year, so I have been a little more careful :).

I also use a hacksaw, but it takes a LONG time (and some sore hands).

I would pick up a bandsaw if I could afford it though...
 
Alright - ordering some fresh hack saw (hand powered) blades and pocketing my $350-400 bandsaw money for now. Thanks a lot everyone...there's probably a porta-saw in my future but I'll do a few knives the hard way first and see if it still makes sense to spend the money.
 
i have the steel i use cut into strips with a plasma torch since it is too hard to cut with a saw. then i use a right angle grinder to cut a groove in the steel and break off what i do not need and then finish profiling out with the angle grinder or disk sander.

you can always get parts waterjet cut. H2Oknife here on bladeforums can cut out blanks but to make it worth the money, it is best to get a bunch cut at once. getting a few blanks cut is not worth the setup time. if you plan on making a hundred or so knives, waterjet is the way to go. http://www.bladeforums.com/forums/forumdisplay.php/869-Waterjet-by-H2Oknife
 
yeah - I hope to be there someday, but right now I'm going to build one or two...see how this knife turns out before I order 100! Thanks for the tip on scoring and breaking though, that's good info.
 
yeah - I hope to be there someday, but right now I'm going to build one or two...see how this knife turns out before I order 100! Thanks for the tip on scoring and breaking though, that's good info.
 
I have a Milwaukee Portaband in a Swag table and I still use the Dewalt angle grinder most of the time. I wear a leather apron, hearing protection and filter mask with a large industrial fan on high speed and saftety glasses. I can cut out a blade in 3 -4 minutes and then I profile it on the grinder. I mainly use the Portaband for bolsters and other small steel cutting jobs. The 41/2 cutting wheels are cheap by the dozen and the method is fast and I don't have to stop and change band saw blades which are expensive. My buffer, drill press, and belt grinder are as dangerous as my angle grinder in my opinion.
 
I'll give the angle grinder a try. I'm not scared of it (in other than a healthy/safety conscious way), I just prefer tools that give me a little better view of what I'm working on.
 
Chop saw and a 40 grit blaze belt on my sander, 10 minutes to profile a blade, if you look around craigslist you can probably pick up a chop saw for $50
 
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