There are many ways to cut blanks from bars, and each has its advocates and detractors. My advice is to start by using the tools you already have access to and see how well they work for what you want to do. Some people only have access to a drill press, and they use that to create a series of holes that they then connect with a hack saw.
I use a HF variable speed portable bandsaws with bimetallic blades. It's slow but effective. When I first started, I used and old Craftsman bench grinder to rough out the profile. It was slower and messier, but still effective. I know some folks just use high tension hack saws. Also slow, and also effective, and certainly less messy. Many use angle grinders. I tried that and didn't like it, but others do. Some even try mounting the angle grinders to tables. That's a VERY bad idea, but some folks swear by it.
I've heard of people using OA torches with cutting heads. Others swear by water jet cutting. Good grief, so many options it makes the head spin. There's probably someone out there that cuts blanks using some high powered die cutting machine. Hey, if you have access, why not.
In the end, where you start probably won't be where you end, but it gets you started. So find your own way, and enjoy. See what about that method you like and what about it frustrates you. That will give you insights into what your next approach should be.
- Greg
!
