I’ve ben doing some handrail work for a couple of years now and recently went out on my own. I just finished a unit with about 45′ of open rail with iron balusters. When I worked for a company I hated cutting iron, but I didn’t really notice how freaking long it takes to cut them with a metal cut-off saw. Now that more time= less money instead of the other way around I am keenly interested in the best way to cut these balusters.
I’m starting a project tomorrow that has about 70′ of rail and am dreading standing at that crappy, loud spark-shooter for the better part of a day. Staring at 210 cuts, give or take, already has me queasy.
Currently using a cheapo Harbor Freight/Chicago brand 14″ cut-off saw with an abrasive wheel.
Any input would be helpful and appreciated.
Replies
Would a plasma cutter work on iron?
I'd have to try the plasma cutter - even if you get a HF one. Then give it to me!
;-)
Forrest
Can you use a porta band? May be able to cut two or three at the same time.
fourquarter
We did a job last winter with probably 150 linear feet of metal balusters.
We cut them with a metal cutting band saw. See the link. We didnt use the Grizzly but most of these inexpensive saws are made by the same manufacturer in China.
http://www.amazon.com/Grizzly-G1010-Metal-Cutting-Bandsaw/dp/B0000DD0AH
Worked well for us, cutts clean, not very noisy, no sparks flying all over the place. Cant beat it.
We'd load about 4 pieces in at once, walk away, when the cut is done the machine automaticly shuts off.
If you didnt want to go this route you can get a portable saw, does the same thing but you have to stand there and phisically make the cut.
Doug
Edited 3/29/2007 6:04 am ET by DougU
Well, obviously a shear is the way to go, but not clear what size semi you'd need to haul an appropriate one to the job.
Otherwise, a portable band saw would seem like a possibility. You can probably rent one to try it out.
I have tried sawzall , jigsaw w/metal bade, grinder and porta-band. The band saw works very well and I picked up a used one from the local tool repair for a great price. On the cheap, a thin metal cutting grinder disc is fast , but still messy and loud.