Cutting metal w/o plasma

BigBody79 said:
I'm just curious to know how much more square plasma is going to be.
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I'm not sure what square plasma is, but if you are referring to a plasma cutter, it would be a lot more for me.

I only have 30amps running to my garage so it would be around 3-500.00 to get the power upped to 100amps
My air compressor is 15 gallon with a CFM of around 4.5 at 90psi. Replacing this is going to be around 5-700.00
Then the cost of a plasma cutter. This would run anywhere from $850.00 for an Everlast PowerPlasma 50 and up.

These are actually listed in order of my "To Do" plan. So, while they are on the horizon, they are a ways off.

On a side note though... if anyone would like to come by and drop off 2 grand, I'd be happy to do reviews on the power install, air compressor and plasma cutter :D

In all seriousness though. It has been a long time dream of mine to have a fabrication business. I first welded with a stick welder over 25 years ago and loved it. I've been working with AutoCAD, off and on for the last 12-15 years. I love to create and design and I have a natural ability for it. So I'm going to try to turn my dream into a business, but I am also 45 years old and refuse to go into debt doing it. I have to take it slow and in steps. I use what I have available and what profits come from that, goes to more tools and equipment. God willing, one day it will come true, but in the mean time, I just like making stuff and learning along the way.
 
I guess my point was that plasma is not going to cut tube any more square than a nice chop saw or nice band saw. Plasma is still operated by hand so it's only going to cut as square as can hold it. Pretty sure even larger fab shops use either a chop saw or band saw for the types of cuts you described. Albeit probably really nice ones.
 
I gotcha... I get my steel at Dillon Supply. They use an industrial cold saw and horizontal band saw for their long stock. Plate they use a shear. The one that they have can go up to 1/2", but they charge $10.00 per cut with it.
 
You made a good choice. I have no experience with the northern brand saws but I have an older porter cable just like it and I love it. I do a shit ton of cutting from 3/4 tube to 1x2 solid bar with mine and have had great luck. Cutting through 1.75 .120 dom takes less than 2 seconds. They are very picky though. Like someone said earlier the material has to be tight and you have to be careful how you cut channel and angle so it doesnt roll in the clamp when you cut. One hop of the blade will ruin it. These saws are very different from cold saws that cut at low speeds. They're more like half way between an abrasive and a cold saw. The blade I'm using now has been on my saw since the middle of January and still cuts great.
 
My FIL has a cold saw at his shop. He has cut a ton of stuff with it. I took 2 of his blades to Cleveland Lumber in Shelby to be sharpened. I think it was around $35 each to have them done. He keeps about 4 or 5 blades on hand.
 
I got Plasma and a Chop Saw, but, 99% of the time I use my Dewalt 7" Cut Off Saw with the thin .045 X 7" metal cutting wheels, (Lowes and HD sell the thin disc sometimes) I get my disc from Random Products. It's what we used when I was a Steeple Jack and stills seems quickest to me. Step on the metal or lock it in a vise - mark it with a silver sharpie - cut away. After awhile you have the feel for it, know how to hold it, and how to get away with crazy cuts without being sketchy, even notching tubing. Plasma I just use for curves and cutting up junk, it leaves slag you have to knock and the cut is kind'a smooth, you need a good compressed air source and a heavy 220V breaker depending on the size. Chop Saw is great if all you do is cut stuff to length and such. Cut Off Saw you can use anywhere you have 110V. Yes, you're throwing sparks everywhere - have fun.

When I say Cut Off I mean 7" disc, disc are cheap if you buy the thin ones (7" X .045") in bulks of 50 ($2-3 each). I've cut 2" by 2" solid bar with it plenty of times, clean and straight cut, plasma and torch you will have a mess. The 7" discs at HD and Lowes are EXPENSIVE - around $5 or so each. 4" grinders are only good for grinding, the wheel is to small to get serious with on a thin disc.

I got Oxy/Act but only use it for heating and bending now.
 
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Is oxy/acetylene not on the radar? It will cut just as good as plasma if you have some skill and set it up right. And the uses are endless. I don't know what I'd do with out my tanks. Well, I'd use a lot more cutting wheels for sure.
 
Plasma for curves / inside corners / places where grinder can't cut and hard to reach areas where grinder won't fit. And use chop saw for straight through cuts on stick stock. The plasma comes in very handy when it's needed but for general cuts, it's not needed. I use grinder when the cut doesn't need to go all the way through. Basically only use plasma when I have to.

The plasma leaves slag only on the opposing side of the cut so I always work from the exposed face of the material if possible.
 
BigBody79 said:
Is oxy/acetylene not on the radar? It will cut just as good as plasma if you have some skill and set it up right. And the uses are endless. I don't know what I'd do with out my tanks. Well, I'd use a lot more cutting wheels for sure.
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I already have an Oxy/acetylene setup. I use it some, mostly for cutting scrap and rough cuts. I'm almost ready to switch over to Oxy/Propane. Have the different cutting tips, just need the Grade-T hose.
 
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