cutting speeds of various techniques

[james terrio]

I'm curious as to how fast you guys are able to cut stock to length, and cut profiles with your chosen tools and techniques. It's been a long time (high-school) since I used a good metal-cutting, liquid-cooled bandsaw, but I don't recall it being all that quick. Clean and cool, definitely.

I have long been convinced of the value of a high-tension hacksaw frame with good blades. They really do cut better than the cheap ones, and the blades last pretty good if you cut forward only. (just like a file). They're not expensive at all, I think I paid $15 or $20 for mine. It makes clean straight cuts but has basically no capability for curves... again, leaving some work to do on on the grinder (but not a deal-breaking amount). There's no question that it requires solid clamping and a little elbow grease. If you have creaky hinges like me, it will get pretty old after a few cuts.

I've been mocked for drilling holes and knocking the waste off with a cold chisel, perhaps rightfully so. It does seem pretty redneck, and leaves more work to grind down to the finished profile. But you might be surprised how quickly it goes. Sometimes there's just no other way to cut weird shapes/curves, especially inside ones, and it's definitely faster than grinding for that purpose.

Actually, water-jet is the king for cutting complex shapes efficiently. But probably 80% of my work this last year has been one-off's and custom orders, so it doesn't make sense to send each blade off to be WJ cut. I'm pretty sure that very few of us can afford to set up a WJ operation in our own shop.

Santa elected to not bring me a porta-band for Christmas; I got a wet tile saw (for G10, etc) and an angle-grinder with cut-off wheels (for metal barstock) instead. As soon as I get a chance, I'll compare each to my old ways of doing it and post my results. It would interest me if you porta-band fellows would take a moment to time how long your cuts take, and give an estimate of the cost involved, next time you do some. With your help, I think this thread could be helpful to others trying to make the most of their budget and time. Thanks!

P.S. let's not leave the hammer-jockeys out of this; I would imagine hot-cutting is about the fastest of all. Please share your thoughts, gentlemen

 

[Justin King]

I spend about 10-25 minutes cutting a profile out of bar stock, depending on the size and intricacy of the design, and also depending on whether the bar is a single blade width, or is wider (can only cut in from one edge without cutting across another blank). My bandsaw is a Porter Cable portaband. It is limited on the radius you can make it cut, and trying to fudge it around corners that are too tight will end up breaking a lot of blades.

 

[tryppyr]

What few blades I have cut with a portaband have involved seven separate cuts. The fits cuts the bar to length. The next two cut in from the sides to establish the base of the ricasso and the width of the tang. The next two come from the bottom and create the tang. The last two are the curved cuts from the point down the spine and the edge. All told, it takes about 10 - 15 minutes.

One advantage of using the saw is that the scrap pieces are usable for other things. Last year I used the scrap from a 1095 blade to make two guards. I used some scrap damascus to make smaller blades. Very little goes to waste this way.

I haven't checked into the hacksaw technique, so I'll probably do that soon. I like the idea of having a tighter turning radius so there is even less waste.

 

[Stacy E. Apelt - Bladesmith]

My modified HF bandsaw will cut most steel at about 1-3 inches per minute, depending on steel type and thickness. A camp knife can take fifteen minutes, or more, to cut out. A simple drop point only five minutes, or less.

Plus one on the high tension hack saw and a quality bi-metal blade. You will be amazed at the difference in cutting ability.

 

[Nathan the Machinist]

My technique is a little different than most, but still 10-15 min from bar to finished profile. Chips, not dust :thumbup:

 

[mgysgthath]

At the moment I'm cutting to length with a hacksaw or angle grinder, and profiling on the 2x72" with a 36 or 60 grit ceramic. It's more work this way, and more wear an tear on the grinder I'm sure. I have built up a little table for my portaband, so I'm going to try that next time.. and if that doesn't go well I'll use the metal cutting chop saw and see how that goes.

 

[Salem Straub]

I've got an Intergram green 4x6 saw that does OK for most stuff, from cutting heavy bar to profiling. The blades are what makes the most difference, I need to find a good source for Bi-metal DieMaster II blades online.

I also have a Dewalt Portaband on my benchtop, still works well and gets used, not appreciably slower than the bigger saw but blades don't last as long.

If I have a piece of steel too hard to saw, I use an angle grinder to rough it out and grind to finish.

 

[jonnymac44]

I've got an Intergram green 4x6 saw that does OK for most stuff, from cutting heavy bar to profiling. The blades are what makes the most difference, I need to find a good source for Bi-metal DieMaster II blades online.

I also have a Dewalt Portaband on my benchtop, still works well and gets used, not appreciably slower than the bigger saw but blades don't last as long.

If I have a piece of steel too hard to saw, I use an angle grinder to rough it out and grind to finish.

Here ya go, Salem. Stacy steered me to this site some time ago. Good folks, good prices.

I'm the same as most, fifteen to twenty minutes to profile a blade. I usually have a small stack of barstock with profiles stenciled onto the pieces. If I have a few minutes of down time waiting for a bit to cool or something I walk over to the band saw and make a few cuts until my fingers get tired and then go back to what I'm doing. On a rare occasion I will sit at the band saw for five or six hours profiling a ton of stuff all at once just to get it out of the way.

 

[GTH11]

Heres some action shots of 4 of the same little hunters in some O-1. Ive been doing things in at least 2's in this case 4, i lay them out strategically place some holes, i run my jet on its slowest speed, i have a saddle seat i sit in, i use my grinder for these liitle dudes to finish the profile, my ol grinder is smooth and quiet, so i can rock out to some tunes and not get in trouble, and in my mind i save on belt use.? I did these guys up including rough hollow in a little of an hour. I like to use a guide to set my plunges on slow speed, once established i kick the guide off and step it up a pulley and get to swayin! I tapered the tangs on these guys and picked some jade G-11 w/ white red white liners, and some canvas micarta with red white red liners for the others! GHaile

 

[Dave Behrens]

I actually prefer my hand held angle grinder for profiling, it takes a little longer sometimes because I love finger groves, but I have become quite proficient at it. I love makin the sparks fly, but I do hate the mess it leaves...and the noise after a long session.

 

[sicily02]

Hi all,

James, I use a Jet bandsaw I got at Menards a few years back. I use 18 Tooth per inch for most (95%) of my cutting. But what I use
even more than my bandsaw is my chopsaw for profiling. I can cut and profile a knife in just minutes compared to using my band saw to cut and profile with. I will use my chopsaw to cut right next to the first cut and just go long the rest of the handle or blade, spine or tip etc. from there. It really is faster than using my bandsaw.

Bryan

 

[Salem Straub]

Here ya go, Salem. Stacy steered me to this site some time ago. Good folks, good prices.

I'm the same as most, fifteen to twenty minutes to profile a blade. I usually have a small stack of barstock with profiles stenciled onto the pieces. If I have a few minutes of down time waiting for a bit to cool or something I walk over to the band saw and make a few cuts until my fingers get tired and then go back to what I'm doing. On a rare occasion I will sit at the band saw for five or six hours profiling a ton of stuff all at once just to get it out of the way.

Jonny, don't see a link?

 

[Bufford]

When working with 5/32 or 3/16 stock knife blanks of less than 9 or 10 inches overall, they take about 15-20 minutes to bandsaw and rough grind into shape. For big choppers and knives 12 inches overall cut from 1/4 inch thick stock, these can take from anywhere from 30 to 45 minutes. No rushing, just a commitment to the long bandsaw journey till the jobs done.

 

[daizee]

I would say 10-15 minutes per blade on a medium-sized ENCO bandsaw.
Profiling might be another 10-15 minutes depending on blade size/shape.

I've done the hacksaw thing when motivated, but it's a lot of work. Now that I usually have multiple pieces in the pipeline, it usually makes sense to work on a different process on an in-progress piece than to try to profile at home without access to my friend's big machines. (this year I plan to build a real grinder.)

Salem has reminded me to get some good new hacksaw blades.
My little benchtop bandsaw is only for wood and other non-metal materials.