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I have always used a small 4" grinder with a metal cut off wheel attached, as long as you have a steady hand and know when to be 'gentle' with the grinder, it works pretty good, the wheels usually dont last very long though, I believe the angle grinders RPM is around 13500.
Another option is the die grinder, I think the cut off wheels for these are smaller than 4" though, but die grinders RPM is usually much higher than a angle grinder, (usually around 23500).
I hesitate to even mention 14" chop saws', Ive had 3 different brands in the past and NONE of them could make a straight cut!
I did just see another tool recently, Im not sure what its called...it looks like a mini sawzall, has a blade similar to a *** saw blade, but its larger, its fairly light, one handed operation, although its still a reciprocating saw with a toothed blade. ( I believe its made for cutting steel mostly).
Opinions, suggestions?
I normally work with 2" angle, steel tube, flats, rectangular, up to about 3-4", generally (1/8-3/16" thick steel)
4” right-angle grinder and cut-off wheel.
That’s my go too! Fast, efficient, and relatively inexpensive considering all other options. I get the cut-off wheels at HF. The 10pack is like $5 with a coupon.
But, if I had to have a metal saw that could cut straight, miters, and bevels- I would seriously consider an Evolution RAGE3.
4” right-angle grinder and cut-off wheel.
That’s my go too! Fast, efficient, and relatively inexpensive considering all other options. I get the cut-off wheels at HF. The 10pack is like $5 with a coupon.
But, if I had to have a metal saw that could cut straight, miters, and bevels- I would seriously consider an Evolution RAGE3.
I looked at the Evolution saw, but Ive never had good luck with cutting steel, with anything other than cut off wheel or sawzall...
I did once try a 'multipurpose metal wheel' on my grinder, it claimed to be able to slice thru steel, aluminum, etc but it didnt work very good at all, it was extremely loud once it hit the piece, and was pretty slow cutting from what I saw. Its been awhile, but if I remember correctly, it had a carbide tip.
I would like to try a die grinder, the one I looked at, it looks like you could mount a 4" cut off wheel to it, they have much higher RPMs than a angle grinder, so in theory, it should cut better, (or destroy cut off wheels faster. LOL)
I forgot to mention Harbor Freight makes a small metal cutting band saw, its the horizontal type and sort of operates like a mitre saw, Im not sure if cuts only straight or can be set to make mitre and bevel cuts.
I use a 4" angle grinder and have a couple of small air die grinders for getting into tight places.
I also have a 2 HP Drillmaster 14" Cut-Off Saw from Harbor Freight. I've had it 10 years and it works great. Cost me $60.
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