Cutting 16 Gauge Sheet Metal?

[Bryan R. Tyler]

I'm going to be getting a rack shelf that I'm going to need to slice a chunk off of. Here's a pic:

The manufacturer said it was made of 16 gauge sheet metal when I contacted them, but didn't specify what kind of metal (I assume steel). I assumed I'd get a strong metal cutting blade for my jigsaw like the Bosch T123X blades, but as I've never cut anything stronger than copper, I wasn't sure if that would be the best way. Would aviator tips/metal snips be strong enough to cut it?

[bongomania]

Those shelves are indeed steel. I've butchered my way through a few of them, and still haven't found a "good" method. Tin snips fail after only a 1/4" or so of attempting to cut. Jigsaw drags the sheet up and down so strongly and quickly that you basically have to bolt the whole shelf down to a 4x4" post in order to get anywhere and not get injured. A Dremel tool is much safer and more accurate, but it takes hours. A handheld rotary grinder with a cutting wheel is very hard to control, and extremely loud against the steel sheet. A hacksaw is just plain masochistic.

There's a specialty hacksaw used by gunsmiths, with a wire-like blade, that might do the best job--if you have the time and the energy.

What I ended up getting the "least bad" results with was a coarse cut using the handheld grinding wheel, and then cleaning it up with a Dremel tool with a grinder bit.

[Bryan R. Tyler]

Well, I have none of those My Dremel died long ago, and everything else I have (minus the jigsaw and an old hacksaw) is for wood cutting. Any idea if a metalsmith shop would cost an arm and a leg? It's a $45 shelf, and I wouldn't want to double that price with new tools for a one-time deal (it's 10ru long and I need to cut it to 8ru).

[LilRay]

Take it to an auto body repair shop, pre marked what you want removed. They have a tool called a "nibbler" that should do the job perfectly.

Shouldn't cost much. Won't take 2 minutes.



God Bless, Ray

[iamlowsound]

If you have string hands, you can do it with hand snips. I have done it with 16g steel before. The easiest way would be with a skill saw and a metal cutting blade. Clean up the sharp edges with a metal file. It should only take 15 or 20 minutes.

lowsound

[TheGrizz]

Why don't you man up and use your teeth?

[line6man]

You can do it by hand with a nibbler tool, but be warned, your hand is going to be sore the next day!

[T-Bird]

Hi.

As a sort of a metal-man myself, an angle grinder and a fine cutting wheel is the answer. Anything else will leave the piece looking like crap, and You have to either buy a new one, or live with that sore sight.

I don't know about the prices over there in US, but over here, an angle grinder that does the job costs around 20€, good quality 1mm wheel: 2€, and I guess You already have safety glasses, hearing protection and heavy gloves.

Regards
Sam

[jonathan_matos5]

http://www.ohiopowertool.com/P-1335-...LAID=435423435

there is a right tool for the job and then there is a tool that can get it done.

here is the right one. look in your tool box for what will get the job done.

[pin_head_47]

A nibbler is awesome if you can find one to borrow. The saw that you mentioned will work, but like Bongomania said, the hardest part is keeping the thing still because it will vibrate so bad from the reciprocation. I've used them on car sheetmetal before and it worked ok, but then the sheetmetal was held in place really well.

[LilRay]

My Pop uses a nibbler on corrugated roofing panels up to 12ga. It cuts cleanly without a lot of burring etc. This is why I suggested it.

Someone in your area will work with you.



God Bless, Ray

[T-Bird]

Hi.

Originally Posted by jonathan_matos5

http://www.ohiopowertool.com/P-1335-...LAID=435423435

there is a right tool for the job and then there is a tool that can get it done.

here is the right one. look in your tool box for what will get the job done.

Well, we obviously come from two totally different schools of sheet metal working, that would be about the last tool in my drawer that I would have used for pre-bent sheet of any thickness. Too much angle deformation and clean up work afterwards for me.

Regards
Sam

[hover]

geez. plasma cutter. amateurs.

[RED J]

a A reciprocating saw with a metal cutting blade turned over and pushed forward cuts 18-16 guage steel like a a champ, very easy to follow a line and no misshaping or distortion.
First hand experience have done it many times. If you need some hints send me a PM.

[DblG]

Originally Posted by Bryan R. Tyler

Any idea if a metalsmith shop would cost an arm and a leg?)

That's an easy job for a place that has the right tools/machinery. I doubt it'd cost very much, maybe the cost of an hour's labor? Just a guess. But the angles would make it hard for a nibbler (IIRC). If they can't do that, my guess it'd be done w/ either an angle grinder or a bandsaw. Or if they have a laser & wanted to cut it on that, but that may be limited to unpainted steel.

[UncleFluffy]

IMO - For a one-off, it's going to take less time to do it yourself with a good quality hacksaw than to take it somewhere else and pay for them to do it.

[Mike N]

Whiz wheel.

[Phalex]

Originally Posted by RED J

a A reciprocating saw with a metal cutting blade turned over and pushed forward cuts 18-16 guage steel like a a champ, very easy to follow a line and no misshaping or distortion.
First hand experience have done it many times. If you need some hints send me a PM.

This. Cover the whole thing with masking tape before you do anything to minimize scratches. When I did metal fabrication stuff, I'd use a jigsaw, and cat to the outside of the line I measured. It's pretty easy at that point to use a bastard file and get things really precise.

Of course these days the fellas have a little handheld plasma cutter that's pretty sweet.....

[Pilgrim]

Looks like a grinder with an abrasive wheel would cut it...but if it were mine I'd take it to a machine shop and ask them what it would cost to cut it. They'd do it clean and fast, and you'd be happy with the result - and still have all your fingers.

Or find a friendly James Bond enemy with the table-cutting laser: