Cutting metal - the options.

I use a angle grinder to cut down to the rough shape close to my lines. Then use a worn out 50grit 3M 977 belt on my KMG and profile 95% of it then take it to the dremel to finish it off.
 
I use a plasma cutter. I'm sure to leave 3/16" or so around the blade edge for the heat affected zone, but It takes all of 30 seconds to cut out a blank. Another 5 minutes on the grinder, and I'm done.

It also comes in oh so handy for other cutting jobs in the shop!
 
I use a H/F floor standing saw (the cheap one). I only use it in the vertical position so I made a few alterations. My butt hurt after sitting on the frame, so I built myself a seat. I used a magnet to hold a 'catch' for the debris. I fabbed together an oiling system that keeps my 3/8" lubricated. I adapted a table from a saw that froze up. It cuts like butter....
 
currently using an angle grinder with a coolant mister to cut down on airborne dust, but I'm looking into acquiring a metal cutting bandsaw.
 
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