Easiest and cheapest way to cut expanded metal??

Polkie918
Polkie918 Posts: 245
edited February 2012 in The Clubhouse
I need an easy and cheap way to cut expanded metal(grill looking metal)....I was at the store today and I was thinking maybe a bandsaw with a metal cutting blade.......or maybe even a dremel tool with metal cutting discs.....


the expanded metal is not very thick and I can cut it with my tin snips but the cuts are not good and bends the metal,...


any other ideas??? thanks
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Post edited by Polkie918 on

Comments

  • Toolfan66
    Toolfan66 Posts: 17,223
    edited August 2009
  • Retro152
    Retro152 Posts: 985
    edited August 2009
    What exactly are you trying to cut?




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  • obieone
    obieone Posts: 5,077
    edited August 2009
    Cutoff wheel.

    +1! the only other alternatives are: sawzall- not pleasant!:eek:
    Or $250 for cordless tin shears:rolleyes:
    I refuse to argue with idiots, because people can't tell the DIFFERENCE!
  • John30_30
    John30_30 Posts: 1,024
    edited August 2009
    obieone wrote: »
    +1! the only other alternatives are: sawzall- not pleasant!:eek:
    Or $250 for cordless tin shears:rolleyes:

    -1, Ixnay on sawzall. That's for cutting stock or rebar maybe. Use a good quality jigsaw with a metal cutting blade, or a composite type blade if it's soft metal.
    Zip right through,
    and accurate too.
  • SolidSqual
    SolidSqual Posts: 5,218
    edited August 2009
  • Polkie918
    Polkie918 Posts: 245
    edited August 2009
    lol for sure cannot use the plasma.....I already have a jigsaw...I guess I could use that and get some metal cutting blades......,.u dont think the band saw would work?

    I need to cut into different shapes with rounded corners and such like for automobile grills.
    Fronts- RTi8
    Center- CSi5
    Rears- FXiA4
    Sub- Velodyne 12"
    Onkyo TX-SR806
    Ps3
    Xbox 360
    65" DLP 1080P Toshiba TV
  • SKsolutions
    SKsolutions Posts: 1,820
    edited August 2009
    For straight lines, a circular saw with cutting wheel 'blade' works very quick. . . you can cut a 4'' cast plumbing stack in less than a minute. I don't know how that would fare on your grill stuff, but for 5$ it's easy enough to find out. Don't forget goggles.

    Flojet would run you a few shekels. .
    -Ignorance is strength -
  • LessisNevermore
    LessisNevermore Posts: 1,519
    edited August 2009
    Polkie918 wrote: »
    lol for sure cannot use the plasma.....I already have a jigsaw...I guess I could use that and get some metal cutting blades......,.u dont think the band saw would work?

    I need to cut into different shapes with rounded corners and such like for automobile grills.


    What guage (thickness) is the sheet?
    I'd go with the 4" grinder and 1/16" cutoff wheels. You can do your straight-line cuts with that, and use some tin snips to round where you need to. You can use a dead-blow hammer to flatten out the bends from the snips.

    Soap stone works great for marking your lines, and I'd tack the whole sheet onto a piece of plywood to keep it in place and keep from cutting into the floor. Wear some leather gloves, goggles, don't remove the guards or handle, and use both hands. Take inventory of your digits before and after the job.:D Seriously, those 4" grinders have some torque behind them.
  • jimmydep
    jimmydep Posts: 1,305
    edited August 2009
    I'd go with the 4" grinder and 1/16" cutoff wheels.

    I use this all the time, very easy to handle and you can make an accurate cut if you take your time.....and don't forget the googles.

    Jimmy
  • kcoc321
    kcoc321 Posts: 1,788
    edited August 2009
    My recommendations depend on what types of cuts, intricies, sizes of peices and guage of materials.

    For long straight cuts, (with a guide) larger radi and larger pieces, the die grinder with cutoff wheels is a good choice.
    Also for smaller pieces and tighter radius, the electric nipper are great, up to 14ga materials. Produce a nice 'finished edge'.They can be had for alot less than quoted above. Here's one that is $49. Not cordless but you probably don't need cordless anyway. Electric shears are alot faster than die grinder.
    http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=92115

    I have also used a bandsaw with fine tooth metal blade. Downside is you need to file edges, if that is important, ie the edges are exposed. Does allow you to work with smaller pieces. Limited in the width of the pieces because of the 'throat' of the saw, usually around 8"-9" on the small benchtop models. Larger on the larger floor standing models.

    Another tool that has not been mentioned is a Beverly shear/ "throatless shear". Must have a workbench top to mount to. Allows for very intricate work, up to 16ga stainless steel. Probably thicker mild steel or aluminum. $99
    http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=38413
    and
    If you are doing alot of it, I would get both the Beverly and the electric. Electric nippers for 'fast' cuts. Beverly to accurate trimming. Die grinder for thicker stuff 'free form'.

    Just noticed you wanted "cheapest" My suggestions are probably not the 'cheapest
    just the 'best'.

    Let's see some pics of your work...:D
  • tanveer amit
    tanveer amit Posts: 1
    edited July 2010
    'Such a useful thread I’ve been looking this topic everywhere!'

    expanded metal

    architectural metal

    metal cladding
  • Jstas
    Jstas Posts: 14,809
    edited July 2010
    Just use an ax. Or a hatchet if you don't have all the space in the world!
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  • concealer404
    concealer404 Posts: 7,440
    edited July 2010
    Reported.
    I don't read the newsssspaperssss because dey aaaallllllllll...... have ugly print.

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  • tnveer42
    tnveer42 Posts: 1
    edited September 2010
    Such a useful thread I’ve been looking this topic everywhere!

    metal cladding

    architectural metal

    expanded metal
  • sucks2beme
    sucks2beme Posts: 5,601
    edited September 2010
    Reported.

    Just use the tin snips and cut it a bit larger, use a grinding wheel
    to clean up, or a belt sander. No use over thinking it. I did this for a
    small project a couple of months ago.
    "The legitimate powers of government extend to such acts only as are injurious to others. But it does me no injury for my neighbour to say there are twenty gods, or no god. It neither picks my pocket nor breaks my leg." --Thomas Jefferson
  • amulford
    amulford Posts: 5,020
    edited September 2010
    I use a four inch grinder and cutting wheels.
  • ShinAce
    ShinAce Posts: 1,194
    edited September 2010
    Seeing that the original post is over a year old, I assume the expanded metal has been cut by now.

    carry on...
  • Toolfan66
    Toolfan66 Posts: 17,223
    edited September 2010
    I'm just posting to add to my post count....
  • sucks2beme
    sucks2beme Posts: 5,601
    edited September 2010
    I'm just waiting for someone to post some good **** links.
    "The legitimate powers of government extend to such acts only as are injurious to others. But it does me no injury for my neighbour to say there are twenty gods, or no god. It neither picks my pocket nor breaks my leg." --Thomas Jefferson
  • zingo
    zingo Posts: 11,258
    edited September 2010
    Cutoff wheel.

    ditto, or metal nibbler.
  • kawizx9r
    kawizx9r Posts: 5,150
    edited September 2010
    I'm just posting to add to my post count....

    I call dibs on whatever you're selling :D

    Could you imagine if the requirement for posting F/S threads was 5k :eek::eek::eek:
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  • danielo
    danielo Posts: 1
    edited February 2012
    SolidSqual wrote: »
    It may not be the cheapest, but it's sure to be the easiest:
    http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200324875_200324875
    164731_lg.gif

    I agree, use the plasma cutter!
  • mrbigbluelight
    mrbigbluelight Posts: 9,716
    edited February 2012
    That DeWalt sheet metal shear is very nice.
    Another alternative to a shear (and we use around here) is a "Nibbler".

    milwaukee nibbler.jpg


    That nibbler pictured goes up to 16 gauge. The one we use will slide though 10 gauge metal like a hot knife through butter but will still make nice, clean cuts in thinner (22 gauge ?) sheet metal without bending/warping edges.
    We still have the original "blade" on the nibbler. We had to replace several jaws on Milwaukee shears (trying to cut through to heavy of metal) before we got the nibbler.

    With some experience, you can make some pretty decent circular cuts. It does waste about 3/8" of metal that it nibbles out, though.
    Sal Palooza
  • Toolfan66
    Toolfan66 Posts: 17,223
    edited February 2012
    Almost 3 years old...