From: jack@ccsf.caltech.edu (Jack Stewart)
Newsgroups: rec.woodworking
Subject: Re: Metal Cutting Tools (was Re: Anyone cut metal with a circular ...)
Date: 26 Jan 1993 19:13:02 GMT
Organization: CCSF Caltech, Pasadena, CA
Distribution: world
NNTP-Posting-Host: laguna.ccsf.caltech.edu

(* Much stuff deleted *)

In article <16B61126B9.EPLUS17@vmd.cso.uiuc.edu>, EPLUS17@vmd.cso.uiuc.edu (Richard Engelbrecht-Wiggans) writes:
> 
> Hi, I'm the one who bought the Milwaukee saw above.  I agree that
> it may not have been intended for metal working, by sometimes I
> have projects for which nothing was designed.  For example, I need
> a very big pot for a big (18 feet tall, 10x15' wide canopy) tree
> in our 2 1/2 story solarium.  The local scrap dealer had a 38"
> diameter double walled stainless kettle.  In testing for leaks, the
> previous owner had over pressurized the thing and blown the inside
> liner inside outish.  I got the 250 monster at 30 cents per pound,
> took it home, and ran a cut around the outside layer just below the
> rim to seperate the two pieces.  (The scrap yard took back the 130
> pound inner peice at full credit, as we had agreed.)  I got a nice
> stainless pot for the tree at under $50 including the cost of the
> saw blades.
>  
> I used my circular saw to make the cut, and a belt sander to
> smooth it (and a cutting torch to cut the other, few connections
> between the two layers.)  What tools would you have used?
>  

A grinder, a belt sander ( + other assorted tools ...).

The last time that I had a job where I had to cut a lot metal was with
a shower door that had to be replaced (it had shattered).  The door
was so badly corroded that it had to be cut away and the frame ground
flat.  I went down to a local tool rental store and renting myself a
nice 9" grinder for about $20 (three day rental).  I was able to slice
through the door and grind the frame flat in less than 1/2 hour.

I think that a grinder would probably have done the job with the
kettle although a smaller (~3") grinder would be better for making
more precise cuts.  A grinder is an general purpose tool that does an
excellent job on stone, concrete, etc.  There may be better tools for
cutting just metal.  A cutting torch will also make good clean cuts
but it probably also cut the inner kettle (which you did not want to
do...).  I've used a disk sander to sand bolts, nails, etc. with no
ill effect.  I would imagine that using a belt sander is similar.

>  
> (Yes, I wear ear plugs, ear muffs, presciption glasses, goggles,
> dust mask, etc, etc, and work on such projects outdoors on the
> driveway so that there is plenty of ventilation.)
>  

I didn't intend to suggest that anyone in this group has slip shod
work and safety habits.  I figure that everyone (in this group) has
the good sense to wear safety goggles.  In my experience, working with
a grinder (espcially in confined spaces, such as a shower stall) is
quite different and unlike working with wood tools.  I figure that
anyone who isn't used to it would be in for a surprise (and perhaps
would be unprepared).  Grinders are very loud.  You need to wear high
quality ear protectors (22db+).  Also I normally wind up covered from
head to toe in fine dust.  Inexpensive dust masks do O.K. but you
usually need to through them away after about an hour or so.  And
before I forget to mention, leather work gloves are a must to keep
sparks and stuff off of your skin.

---Jack

-- 
Jack Stewart                                     E-Mail: jack@CCSF.Caltech.EDU
Caltech Concurrent Supercomputing Facilities,     Phone: 818-356-2153
Mail Code # 158-79, 391 S. Holliston, 
Pasadena, CA 91125.                            #include  <std.disclaimer>