Does anyone have any ideas on a durable saw for metalwork that I can get through a hole?

I burned out my jig saw (skil saw that lasted about 20 years) and need to replace it. What really stressed it was cutting metal and I found a larger reciprocating/demo saw blade that had a small enough shank to fit the jigsaw that I used to cut thick wood - too much blade for the saw.

What I want is a band saw with a strong motor. I can swap blades for cutting metal and wood. The problem is I can't get a band saw blade through a hole to cut from the inside. Half of my projects involving metal have some kind of interior hole I need to cut - fitting electronics in dash consoles (rectangular holes), cutting holes for fitting pipe in square tubing (in place of hole saws), ect. I like the versatility of a jig saw with an adjustable angle plate, and the Skilsaw I have even has a rotating shank so I can set the blade at any angle with respect to the rest of the unit - cut sideways, backwards, or at an angle. That is really handy when cutting in wood or drywall with the hole horizontal.

Is there such a saw that exists that is more robust (table/bench top even) than a jigsaw and will hold up to cutting metal while being able to get a blade through a hole?

I'm starting to think I need a band saw regardless - for the exterior cutting and straight cuts that might be the best and keep wear off of a jigsaw....

I'm down to a hand-held circular saw (another skilsaw - I like them a lot) and 4.5" angle grinder with cutoff blades for cutting metal. I can't cut circles with either, though I can plunge cut for inside holes if they are big and straight enough.....

 

Next size up is a sawzall -- and they're generally pretty heavy and a bit awkward. But they're powerful and there are a lor of blades available.
Maybe somebody makes a smaller one.

But, I wouldn't necessarily give up on jigsaws --it might just be part of the cost of your business - replacing the saw from time to time. ALso, there might be an industrial version that's more rugged.

hj

 

Really a jigsaw is your best option. Or upgrade to a plasma.

 

Sounds like you need a band file.

My dad has a DoAll brand one very cool. It is like a vertical industrial band saw but the blade has short sections of file riveted to on 1 end allowing it to go around the pulleys. the blade has a seam in it so you can take it apart and feed it thru a hole and file it out to square or whatever you want.

Hand held ones with sand paper are also great depending on what the material is.

 

Have you tried a body saw? They come in electric and air operated. The blades come in fine and course tooth.