Best way to detail cut galvanized steel

[Dustin Crops Boy]

I need to do some detailed and round cutting on some 26 gauge galvanized sheets. I tried every bit in my Dremel arsenal (well, the basic bits that it comes with) and the only one that really cuts it is the reinforced cut off wheel. That's great for straight cuts - but I have some smaller round cuts that need to be made.

Besides lasers or some other crazy thing I probably don't have - what is the best way to cut this stuff with some bit of detail?

 

[cheech9898]

Only suggestion I would have is renting a plasma cutter. Short of that, use the cuttoff and get close to your line and clean it up with a file or a small jeweler hacksaw if the letters are wide enough to allow it.

 

[MML]

Only suggestion I would have is renting a plasma cutter. Short of that, use the cuttoff and get close to your line and clean it up with a file or a small jeweler hacksaw if the letters are wide enough to allow it.

Was just about to say that - a laser cutter or waterjet... are there any engineering shops near you?

 

[itsalive]

Waterjet is best. Less clean up work. The thickness of the material could be a blessing for you. I've had parts cut out of 3/16 stainless and you have to pay for the table time, and the material. It can add up real quick, but it's so worth it. Too bad I've yet to sell a single item based on all that work and money used to make the proto. I took a die grinder to the part with a 60 grit sanding wheel, and it cleaned all the edges up smooth as butter. Chased it again with some higher grits until I got to 1000, and oh man it was just like looking in a mirror.


Go waterjet if you can.

 

[hlo]

Be careful when cutting galvanized metals. The galvanizing contains various metals such as zinc and lead. The zinc can heat up and vaporize and you don't want to inhale that stuff. Leads to headaches, sickness, and with enough exposure heavy metal poisoning. In other words HIGHLY TOXIC! I suggest you do this in a ventilated area with a blower or do this outside.

 

[Honus]

If you need to do it by hand then use a nibbler. The hand held units cost under $30 and you can get air powered ones as well.

Here's the one I use-
http://www.mytoolstore.com/klein/76011b.html

I used it to cut out a whole bunch of small/thin stainless steel parts and it works like a charm.

 

[Dustin Crops Boy]

That nibbler sounds like a perfect option for my needs. Thanks.

 

[00MrNotWrong00]

this is the bad dog nibbler http://www.thisoldhouse.com/toh/photos/0,,1618919_1362706,00.htmlI've seen it for less than what it's shown here, This is the only tool I've ever picked up at a tool show that has knocked my socks off. The little handle lets you turn it as you cut. I'm going to be picking up one of these myself the next time the show comes through.

 

[Dustin Crops Boy]

Wow- that bad dog is amazing! Bit pricey for my one off small project - but definitely something I'll keep in mind if I need to do a bigger project

 

[Sidewinder]

You can do gentle curves with nibblers. I'd use half round and round files (and elbow grease) for smaller ones.

SAS