[Shop-talk] notching metal

[Jim Stone]

I’ve used a cutoff wheel in my Dremel before for smaller cuts, finishing the corners with a jigsaw.  3/4” is pretty narrow and you might have to cut from both sides to get all the way through, but the jigsaw cleanup should be pretty easy after that.  Most Dremel cutoffs I’ve tried are crap that break way too easily, but I’ve had good luck with the EZ Lock wheels.  https://www.amazon.com/Dremel-EZ406-02-Cut-Off-Mandrel-Cutting/dp/B000FBLRVA/ref=sr_1_5?crid=117BCIAHMHP0P&keywords=dremel+ez+lock+metal+cutting+wheel&qid=1578158034&sprefix=Dremel+e%2Caps%2C151&sr=8-5 <https://www.amazon.com/Dremel-EZ406-02-Cut-Off-Mandrel-Cutting/dp/B000FBLRVA/ref=sr_1_5?crid=117BCIAHMHP0P&keywords=dremel+ez+lock+metal+cutting+wheel&qid=1578158034&sprefix=Dremel+e,aps,151&sr=8-5>. 

> On Jan 4, 2020, at 11:56 AM, Pat Horne via Shop-talk <shop-talk at autox.team.net> wrote:
> 
> Easy, plasma cutter!
> 
> John, this is not an easy task. I’d try a combination of methods. Once the sides are cut, holes are drilled & piece is broken off, grab the jig saw to clean out what’s left. 
> 
> Is it crucial that the notch have a square bottom? If not just use a Large bit to drill out a hole to give you a radiused slot bottom. 
> 
> Pat Horne 
> We support Habitat for Humanity
> 
> 
>> On Jan 4, 2020, at 9:27 AM, john niolon via Shop-talk <shop-talk at autox.team.net> wrote:
>> 
> 
> 
> Need some metal working expertise.  I know there is  a simpler way to notch metal than what I’m using.  I had to fabricate a latch thingy for a neighbor using 3/8” plate which required a rectangular notch to be cut in the plate about 3/4” wide and 3” deep.  I used a Metabo grinder with a .040 cutting disc to cut the sides but how to cut the back end of the notch.  I thought about a saber saw with a metal blade but the notch was very narrow and it would have been difficult in that small area. Guess I could have used a hole saw at the back of the notch and then squared up with a file...
>  
> I couldn’t reach in the gap with a 4.5” grinder to hog it out... finally I drilled a number of holes across the back line of the notch, broke out the slug and finished it with a file to make it square.  There has to be a better way.  Can’t find a hand tool to handle 3/8” material and notching machines aren’t in my budget.. 
>  
> give me some suggestions and options or ideas, that haven’t dawned on my feeble old brain !
>  
> john
> 
> https://jniolon.classicpickup.com/
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