Cutting perfect slits on bars.

conordavidson

conordavidson

Member
So yea, I want to learn how to cut perfect slits on bars and what tools I need to easily accomplish this. Originally I just used a hacksaw and cut either side. It works fine but it's not perfectly straight and they're pretty thin. I then purchased a dremel with tungsten carbide cutting bit, but that cuts really slow and goes crazy around the metal and makes them extremely crooked.

So how is it done? I know you can do it with a mill, but those cost $1000s. Is there any cheaper (around $100-$200) tool that I can use by myself, instead of going to a machinist and getting them done?
 
S

SOA

Steel Member
Drill press for the holes, cost under 50 usd for a press which the ones u could fit your hand drill into thats your cheapest option

the slits i use a angle grinder there also cheap & just cut them out with the blade use a think one for the slits be 2 to 3mm wide easy
 
Mr. Proto

Mr. Proto

Member
Harbor Freight angle grinder with a 5" cutoff wheel is basically the cheapest thing you can use. Probably under $50 plus you can use it to shorten your bars height and width if you get new stuff or cut down forktubes if you ever need to or seized clamp bolts. It's pretty universal and handy. An endmill is the best though but pricey for a mill.
 
C

coryM

Member
dude a chopsaw would work if you held the bar by hand. A mill is really the most accurate way though. They make mill style tables for drill presses that are cheap. like under 1 or 2 hundred. example: http://www.use-enco.com/CGI/INSRIT?PMAKA=201-2826&PMPXNO=951820&PARTPG=INLMK3 Ive never used one so idk about how good they are. but i imagine they work decent...

That should work fine for slots since slots are basically by eye. But I wouldnt try to use one of those for anything thay gets technical haha
 
K

keons5

Collin Snoek
Don't get the table attachment for your drill press; it will be a nightmare. Drill presses are far different from mills and are not built the same at all. If you use a x and z axis it will put to much pressure on the chuck and spindle and eventually it will become loose and therefore ruined. You could also run the risk of ruining the bearings among other things.

Use an angle grinder with a fresh cutting blade. These are cheap and very effective. It's very possible to achieve a good cut with an angle grinder if you have the patience.
 
conordavidson

conordavidson

Member
With the angle grinder, would I still have to cut it by eye? And how do you use them, just drop it in vertically into the end of the tube so it cuts through? If that's right, couldn't I just use some high tensile strength metal cutoff blades on my dremel or is it not strong enough?

A lot of questions, but I still have more.

So I checked out "harbor freight" and this is what it came up with: http://www.harborfreight.com/cpi/ctaf/Category.taf?CategoryID=104&pricetype

I'm not sure which one to pick out of those, so if I could get some help. Obviously I need 5" or greater if I need a 5" cut off blade, but I'm still not sure on which one would be best.
 
K

keons5

Collin Snoek
I can't see the link because I'm in school. I'd imagine you could find a blade for a dremel similar to the link I posted.

Link
Link


I use an angle grinder for all of my cuts unless I go to the shop. You do have to cut by eye with an angle grinder. Angle grinders have some weight to them unlike a dremel, so I imagine they would be more stable and get a straighter cut. To slit the pipe you just work from the bottom end up slowly. If you get a thin metal cutting blade, the grinder goes through it like nothing. With the thicker grinding blade that normally comes on them, there is usually an amount of instability and the blade won't cut straight in. The grinding blade will wander on top of the metal since it is not designed to auctually cut.

You could just buy some cutting blades for your dremel. I would imagine cutting higher grade metal with a dremel could be challenging. It could definitely work if you had a fresh cutting blade, but it might be hard to keep the cut straight and even. If I were you I would try this first before buying any other equipment. I have actually bought dremel cutting blades at harbor frieght and northern tool. I've seen them at Lowe's as well

I imagine your link was for a cut-off saw even though I can't see it. Depending on your budget I would purchase a standard 14" cut-off saw. That way you can use it for a large variety of projects. Building jigs for cutting pipe on cut-off saws is rather easy. There are holes for jig mounts on most metal cut-off saws. A lot of people build collector jigs for cutting pipe at specific angles use when building exhaust collectors on cars. Building a sturdy jig for cutting the slist accurately would be rather simple. I'll try to dig up some links later.

Another option would be a die grinder which is the equivilent of a dremel on roids. These can usually be picked up at local pawn shops for next to nothing. However, you do need at least a decent air compressor to run one. Watch out buying used ones as the bearings can be shot. If your dremel works ok, then chances are that this would work a little better. Sorry about the long response, I'm bored in school haha
 
B

blaine142

Member
conner if u order one of those angle grinders it doesnt matter which one they will all work but the ones with the horizonal blades will probably work the best.

EDIT: i have one of those 4-1/2 ones and they work fine, and u can cut like anything within seconds
 
Lil Steve

Lil Steve

Member
blaine142 said:
conner if u order one of those angle grinders it doesnt matter which one they will all work but the ones with the horizonal blades will probably work the best.

EDIT: i have one of those 4-1/2 ones and they work fine, and u can cut like anything within seconds
Click to expand...
Seconds? :O
 
A

alexiorio

Member
StevenEsposito. said:
blaine142 said:
conner if u order one of those angle grinders it doesnt matter which one they will all work but the ones with the horizonal blades will probably work the best.

EDIT: i have one of those 4-1/2 ones and they work fine, and u can cut like anything within seconds
Click to expand...
Seconds? :O
Click to expand...
Angle grinders are amazing, they cut through even chromoly and steel like butter.
 
J

JonnyJonDogg

Member
StevenEsposito. said:
blaine142 said:
conner if u order one of those angle grinders it doesnt matter which one they will all work but the ones with the horizonal blades will probably work the best.

EDIT: i have one of those 4-1/2 ones and they work fine, and u can cut like anything within seconds
Click to expand...
Seconds? :O
Click to expand...
 
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