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Rough Cutting: The Limiting Factor in Your Shop?

Aug 11, 2016   //   by Bob Warfield   //   Beginner, Blog, CNC Projects, DIY CNC, Manual  //  7 Comments

If you ask most home shop and DIY machinists what the limiting factor is in their shop, I suspect they’d respond that they need a bigger mill or lathe, or they need their first mill or lathe, or they need more room, or something along those lines.  Years ago, when I was starting out as a DIY machinist, my limiting factor was always the ease and convenience of rough cutting stock.

It isn’t that I had the world’s greatest mill and lathe from the get-go, because I didn’t.  They were a pretty average RF-45 mill and Lathemaster 9×30 lathe.  They were typical crotchety Chinese hobby machines, and I don’t miss them too much, but I got a lot of projects done with them and without too much complaining.  It took me a long time to realize it, but where I was fussing and cussing the most back then was in cutting rough stock to size before I could even get it to those machines.

I was a packrat for raw metal back in the day.  Plates, structural steel, and long rounds were piled all over my garage shop.  Almost all of it was too large for my machines, so before I could do much of anything, it had to be cut down to size.  I started out life with the ubiquitous little Harbor Fright Band Saw:


The ubiquitous HF Bandsaw…

I paid all of $41 on eBay for the thing (it had some cosmetic issues), bought a decent Starrett bimetal blade for it that cost more than the saw, and proceeded to hate on the little stinker through many projects.  What you see is what it looked liked towards the end of its useful life.  I’d mounted it on a cart (for more storage and portability), added a nice table for upright work (normally it saws in horizontal mode), added a little oil dropper to lubricate the cut, and generally learned how to tune it up to work with the minimum of hassles.  After all that, and especially after I learned to tune it up, it was decent, but very slow and still somewhat finicky.  What do you want for $41?!??

The Perfect First Cut-Off Saw?

Somehow, I came across what would’ve been a far better initial purchase–a DeWalt Multicutter.  Here’s a shot of it in action:

DeWalt Multicutter

My DeWalt Multicutter in the middle of a messy shop…

Wow, what an improvement!  This is a poor man’s cold saw, and just the thing for DIY CNC’ers.  It’s basically a carbide toothed saw blade in a miter box format with a motor that spins it slow enough (still much faster than a cold saw) so the blade can live.  I’ve sliced through everything from cast iron to make a table for a disc sander to endless aluminum stock to steel tubing.  It’s so much faster and easier that despite having a full-sized industrial band saw now, I still go to the Multicutter for any kind of smallish diameter long stock and save the bandsaw for plate work and curves.

I’ve used a lot of abrasive cut-off saws, and I like this thing so much better.  The price is actually pretty reasonable–you can buy one on Amazon right now for $435, direct from DeWalt with free shipping.  It just beats the heck out of fighting with a cheap bandsaw.

Here’s what they look like without all the clutter:

DeWalt Multi-Cutter

A DeWalt 14″ Multi-Cutter Carbide Chop Saw…

A pro-shop is going to have much better solutions, but even pros might find one or two of these to be handy in a corner for quick and easy work while the bigger machines are busy.

The blades actually last a lot longer than I expected.  Mine could use a new one, but still cuts.  I plan to drop it by the local saw blade sharpener and see if that’s a cost effective way to renew it.  If not, new blades are not that much either.

Okay, But What’s Even Better?

For a DIY situation, I’m not sure there’s much better.  Of course you can order your stock cut to size, but that prevents you keeping much on hand. You could buy a bigger nicer bandsaw–I took that route when I found a gorgeous Delta Industrial Bandsaw that had been fully restored:


Sawing aluminum plate on the Delta…

I love the Old Beast, and it is just the thing for sawing plate like I show in the photo above.  I stuck a VFD on it to deal with it’s desire for 3 phase (not available at home for me) and use it a lot.  But for stuff that fits on the DeWalt, I keep going back to it.  It’s faster and more convenient than the Delta.  In fact, if I had a CNC Router table, I wouldn’t have much use for the Delta, except perhaps for cutting harder materials like steel or cast iron.

Horses for courses, as they like to say.

For really big plates, I fire up my ESAB plasma cutter from time to time.  I can’t wait for someone to come out with a reasonably priced small-scale Waterjet machine–that would be the ultimate.

Meanwhile, look into that DeWalt and keep eyes peeled longer-term for a really nice bandsaw.  You won’t be sorry!


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Rough Cutting: The Limiting Factor in Your Shop?
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  • Cold cut saws are amazing. They also leave the shop much cleaner than abrasive saws.

    Harbor Freight sells a great hand held metal cutting circular saw for around $100. I had good luck with their metal cutting blades but your performance may vary. Morse is my back up for cold cut metal cutting blades.

    My very first cut was through a 1 X 3 inch steel flat. Actually thinner steel is harder to cut because you need to prevent chatter which will chip the teeth.

    Cold cut blades require a much slower speed and will burn up in wood cutting saws.

  • I would highly recommend the Evolution Tools Steel Saw II. I have owned mine for 4 years. I bought an extra Aluminum blade .The blades last 3000-4000 cuts for me. I cut a lot of 3/4″ square solid 6061. I have cut as large as 3″ x 3″ Solid 6061. Last summer I cut a 4″ x 2.8″ (.326″ web) I-Beam with the steel blade. it cut way easier that I thought it would. I also have an import portable band saw. I discovered you can buy a 3 pack of Lenox blades for $19. Made a huge difference over the import blades.

  • I just purchased the evolution rage 3 saw, which is similar to the dewalt you showed but a bit cheaper. The blade is engineered to cut wood steel and aluminum. Good enough for almost anything a hobbyist will encounter.

  • Bob do you know where I can purchase a bandsaw blade cutter? I don’t need the welder. Some of my high school kids decided to see how many blades the thing would cut at once, and broke the casting, which is screwed into the frame of the machine. It wasn’t much of cutter, too hard to get the sawblade perpendicular to the cutting knife.


    • I don’t know where you can get a cutter by itself, sorry!

  • These cut off saws aren’t just for amateurs! I work at a production shop that runs a lot of brass, bronze, stainless, monel, etc. rod, and unfortunately, a lot of it has bends in it that don’t agree with our bar feeders. So, we just use the exact same DeWalt model you showed, cut off the kinky end, and away we go. The only real difference is the blade we use. Rather than a toothed blade, we use an abrasive blade. Cuts through anything, and never breaks.

  • […] This post originally appeared on the CNC Cookbook blog. […]

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