Cutting Metal need some tips/pointers

[Korr]

Hi guys! So i found an unused piece of metal that is big enough for me to cut out two traingle shaped side panels for my 78xs1100 yay! I do not know what type of metal it is, but it is 1mm thick. What would cost me $30 or less to cut this? It's 27" long x 16 1/4" wide and weighs about 4.7 pounds. I found it at work so i can't really do much to it atm. Is there a simple way to identify the metal? What tools would i be able to use to cut this pretty quickly for under $30? Thanks for listening guys!

[madmax-im]

Hi guys! So i found an unused piece of metal that is big enough for me to cut out two traingle shaped side panels for my 78xs1100 yay! I do not know what type of metal it is, but it is 1mm thick. What would cost me $30 or less to cut this? It's 27" long x 16 1/4" wide and weighs about 4.7 pounds. I found it at work so i can't really do much to it atm. Is there a simple way to identify the metal? What tools would i be able to use to cut this pretty quickly for under $30? Thanks for listening guys!

Thats a good one what color is the metal...? A pic might help...

[Korr]

Here's the picture. The whole thing is painted white even where the holes are. I'm at work right now so i can't mess with it anymore hehehe. I am also thinking of a quick release system like the type on lunch boxes Instead of coming completely off, it will open like a door!




wow i just realized i have alot of material left over. I can use that to mount mount the rear fender like a tire hugger

[madmax-im]

Looks like the best way to cut that would be on a band saw...rather than a hand held tool

[BigDick]

that or hammer it out flat along those breaks, then use a cut off wheel in a die grinder or one of the fancy purpose die grinders.

[Korr]

Oh sorry i forot to mention the only power tool i have in my arsenal is a dremel lol!

[tarzan]

I agree with Bigdick,cut off wheel.You might be able to cut it with snips.It is probably mild steel.If you are lucky it might be aluminum.Try a magnet.Is that just paint or powder coat?

[b.walker5]

Harbor Freight has cheap angle grinders for 19.99 and 10 cut off discs for 5.99, so for 26.00 you could do the job, but depending on the type of metal, any good tip snips should cut 1 mil okay, I'm talking , Klenk, Wiss or Gilbow etc, not some of the many chinese "aviation snips" that are around.

http://www.harborfreight.com/cpi/cta...emnumber=91223

[Korr]

Great! There's a harbor freight about 10 minutes away from me. I'll give them a try

[TopCatGr58]

Hey Korr,

My bet is also mild steel, a magnet will probably stick to it to confirm that. A dremmel cut off disc will work, but will take some time, and several discs! A cheap HF electric grinder/ using a large 4" or 4.5" cutoff disc will make short work of that. Don't forget the eye protection, but you knew that!

You will possibly want to think about leaving some extra material beyond the size that you want, so that you can ROLL or bend over the ends so you won't have such sharp edges to deal with when handling them. I'll see if I can find a few photos from a guy that made some tins for his sidecovers. Another idea would be to get some of that fender trim stuff, that is self adhesive and could be put around the sharp edges and make an accent at the same time!? Forgot to mention, use some thin cardboard as templates and fit them to the sides first, and then once you've figured out the right sizes, then use them to trace out the pattern on the sheet metal for cutting.
T.C.

[fredintoon]

Hi guys! So i found an unused piece of metal that is big enough for me to cut out two traingle shaped side panels for my 78xs1100 yay! I do not know what type of metal it is, but it is 1mm thick. What would cost me $30 or less to cut this? It's 27" long x 16 1/4" wide and weighs about 4.7 pounds. I found it at work so i can't really do much to it atm. Is there a simple way to identify the metal? What tools would i be able to use to cut this pretty quickly for under $30? Thanks for listening guys!

Hi Korr,
see if a magnet sticks to it. If so, for under $30 the best way to cut up that folded part is to borrow a Skillsaw and buy a metal-cutting abrasive blade to go in it, last one cost me ~$6.
You will need eye protection and ear defenders to combat the stream of sparks and the appalling noise. But the methodology will cut sheet metal without warping it, unlike using tinsnips.

[xswilly]

you could use a jig saw with a fine tooth blade
prob get one at walmart for 19.99

[MaximPhil]

you could use a jig saw with a fine tooth blade
prob get one at walmart for 19.99

If you go with a jig saw. nail or screw to a scarficial piece of thin plywood.
will work for either alluminum or steel. practice on a pice before cutting your shape.
Phil

[BigDick]

tc beat me to it, I forgot about the angle grinder set up with the cut off disc or really thin grinding wheel, I have one of those too.

[crazy steve]

I'll give you the REAL lo-buck option.....

Got a Skilsaw? Can you borrow one? Take the wood blade off and turn it backwards. DON'T use a carbide-tipped blade, the cheapy ones work better and have at it. Oh yeah, this will noisy as hell, will give you a semi-decent cut (no worse than any other cut-off-type blade), and throw the blade away when you're done. 1 mm may be a little thick so don't be in a hurry.

Yep, this is real cave-man tech, but it does work. I've cut metal roofing several times this way when the roofers didn't leave me a hole and all I had was a Skilsaw. Never my first choice, but in a pinch....

'78E original owner