Best cutting tool for patch panels?
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More Turbo
Joined: Nov 2004
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From: colorado
Best cutting tool for patch panels?
What is the best tool you all have found for cutting out your rusted spots? I found a cheap air cutting little grinder at Harbor frieght and it seems that anything this would be able to cut through -I could have just as well used scissors! Due to recent budget cuts in my current administration I'm afraid a plasma cutter is out off the question!
Hotshot
Joined: Jan 2001
Posts: 16,887
Likes: 3,129
From: SE Wisc. (the Rust Belt)
I would love to have a plasma cutter too! I use either a sawsall, jigsaw or angle grinder with a thin disc. I cut out a lot of bad sheet metal this weekend. I hold the sawsall at an angle if there is some bracing behind the piece of sheet metal I am trying to cut out, allowing just enough of the blade to cut without jumping out of the sheet metal and not hitting the bracing behind.
I also have a electric hand held shears that works great for cutting new flat sheet metal for replacement panels.
I also have a electric hand held shears that works great for cutting new flat sheet metal for replacement panels.
Postmaster
Joined: Jun 2004
Posts: 4,190
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From: Riverside, So Cal
I have done some patch panel work and find my 4 1/2 angle grinders to be the handiest tool for most places. I have two of them. One uses a cutoff wheel and one has a flapper disk for dressing and prepping the edges of the cutout. Mine are from Harbor Freight.
For the patch panel itself, I sometimes also use a pistol-grip air shear to cut the panel from a larger piece, then the grinder with flapper wheel to dress and size it.
I have a basic hammer and dolly set and panel bean bag to form shapes.
For the patch panel itself, I sometimes also use a pistol-grip air shear to cut the panel from a larger piece, then the grinder with flapper wheel to dress and size it.
I have a basic hammer and dolly set and panel bean bag to form shapes.
Post Fiend
Joined: Sep 2004
Posts: 5,231
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From: Near Fresno, California
I have one of those Harbor Freight air operated cut off wheels - works ok for me, but it is a hog for air. I also have some air sissors to use on new metal, and a sears saws all for heavy peices, but I don't think it would work so well on sheetmetal.
Sometimes the best is a cut off wheel installed on the skill saw - just depends on the size of the job. The cutter I like to use the most is the fire wrench, but it is too messy for most sheetmetal work.
HF has an air operated sheet metal saw (looks like a scaled down saws all) that I have been tempted to try - been waiting for it to go on sale.
Sometimes the best is a cut off wheel installed on the skill saw - just depends on the size of the job. The cutter I like to use the most is the fire wrench, but it is too messy for most sheetmetal work.
HF has an air operated sheet metal saw (looks like a scaled down saws all) that I have been tempted to try - been waiting for it to go on sale.
Senior User
Joined: Aug 2000
Posts: 288
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From: Agua Dulce, So. Calif.
Originally Posted by rhw
What is the best tool you all have found for cutting out your rusted spots? I found a cheap air cutting little grinder at Harbor frieght and it seems that anything this would be able to cut through -I could have just as well used scissors! Due to recent budget cuts in my current administration I'm afraid a plasma cutter is out off the question!
I have avialable, plasma, cut-off wheel air grinder, and mini air saw, and others for my most accurate work I like the mini air saw I got it at Harbor Freight and my boy has used others made by snap on and others and says it works equally well. (this particular tool only) we are able to follow a line very accurately. good luck Ed ke6bnl
Hotshot
Joined: Oct 2004
Posts: 15,882
Likes: 88
From: Durham NC
I use my Makita 4" angle grinder with a cutoff disk for most of the cutting work I do, it can be used very precisely on thin sheet metal to very heavy stock. Trick is to use it like a chop saw, rotate the disk into the work until it cuts thru then move down the line and repeat, don't try to pull it along the line. The grinder is very inexpensive, I got mine at Costco for <50.00, they are ~65.00 at HD or Lowes. I switch to a grinding wheel or flap wheel (my favorite) for dressing down the cuts or welds. Never try to use a cutoff disk as a grinding wheel they are not meant to be used from the side.
I buy the cutoff disks online by the 100, that makes them very cheap, which is a good thing, I go thru 2 or 3 a day.
BE SAFE when using any rotary tool, wear a full face shield! The cutoff wheels will come apart if you bind them and they throw a lot of sparks and small pieces with a lot of force. Also wear heavy leather work gloves, a small slip can leave a nasty gash in an instant, and the pieces get very hot.
I also have an electric sheet metal shears for making long cuts in new sheet metal, but I don't use them for cutting out old metal.
I buy the cutoff disks online by the 100, that makes them very cheap, which is a good thing, I go thru 2 or 3 a day.
BE SAFE when using any rotary tool, wear a full face shield! The cutoff wheels will come apart if you bind them and they throw a lot of sparks and small pieces with a lot of force. Also wear heavy leather work gloves, a small slip can leave a nasty gash in an instant, and the pieces get very hot.
I also have an electric sheet metal shears for making long cuts in new sheet metal, but I don't use them for cutting out old metal.
Posting Guru
Joined: Feb 2002
Posts: 1,392
Likes: 2
From: Michigan
I'll echo the use of an angle grinder, although I tend to stay away from the lower dollar (HF) models... had a bad experience with one when the bearing gave out... not pretty... you get what you pay for
Anyways, currently use 4 1/2 Dewalt, with the thinner cutoff wheels. They slice through sheetmetal like nothing. I then use flap sanding wheels (the ones that look like a normal 4 1/2 grinding disk, but are glued stacks of sandpaper) to clean up any rough cut sheetmetal, as well as for the final fitting of the patches
Anyways, currently use 4 1/2 Dewalt, with the thinner cutoff wheels. They slice through sheetmetal like nothing. I then use flap sanding wheels (the ones that look like a normal 4 1/2 grinding disk, but are glued stacks of sandpaper) to clean up any rough cut sheetmetal, as well as for the final fitting of the patches
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Posting Guru
Joined: Oct 2003
Posts: 1,552
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From: Adams,CO.
Rob, I use the HF mini sheet metal saw 39.00, an air grinder 19.00, a hand nibbler 35.00 and a die grinder 15.00 for all the work I have done, at these prices and being made in China, they crap out, I toss out. Can't go wrong.
The mini saw can use hacksaw blades if you cut into 5-6 pieces from ea blade saving more bux. Happy cutting.
The mini saw can use hacksaw blades if you cut into 5-6 pieces from ea blade saving more bux. Happy cutting.
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Posting Guru
Joined: Apr 2001
Posts: 1,150
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From: Waynesboro, Virginia
Dittos on the 4" Mikita from Costco with the cut off wheels. I just recently started buying them off the net in 100 packs too. Since I am in the ceramic tile business I know that the same tool does great on the smaller tiles, especially on kitchen backsplashes, on the switchplate cuts.
Hotshot
Joined: Oct 2004
Posts: 15,882
Likes: 88
From: Durham NC
Thanks Tim! I'm going there to get one, I get tired of constantly changing wheels from cutoffs to cut the parts to flap wheel to shape and smooth welds. Next problem will be to keep the cords from tangling!
Post Fiend
Joined: Sep 2004
Posts: 5,231
Likes: 1
From: Near Fresno, California
Harbor Freight had them as a special last month - $9.99 or maybe $14.99. I bought two as they were real cheap. I thought they would be cheap tools and not much good, but I actually like them better than the Sears one I have been using for years.