What tool do you guys use to cut body sections with?

[Russell Ashley]

I've noticed that some of you can cut a long perfectly straight line when doing panel replacement. What do you use? I use a die grinder that is rated at 20K RPM with a thin three inch brasive cut-off wheel that is also 20K RPM rated. It seems that I can never get a long cut as straight as some of you. The wheel grabs and the cut winds up a little crooked. Is there something better to use than the cutoff wheel? I've got major surgery to do on my drivers door soon and it looks like I will need a straight cut across the door to fit up a new lower door skin. I don't mind buying a new tool if there's something better out there.

[skip99]

I use a 3" die grinder also, but I have played with a few different blades and the cheaper ones will grab and fluff? out...
use a better blade and thin 1/32 -3/64..
I've tried body files and jigsaws. 3" cuttoff saw works the best for me

[Newtz67]

I've never tried it myself, but I know some guys use a sawzall. I use one at work all the time and I'm pretty sure if you tape the line you wanna cut and take your time it wouldn't be tricky to get a straight cut.

[pgf545]

I use various tools to get my cuts. By far my favorite is a 4" angle grinder with a .040ish thick wheel....they may be 1/32...can't remember. I like to use some tape to guide my cut like. Also don't try to take it all in one whack, take several small steps and go over the area several times that seems to take the wheel grabbing away. I also will clean up the cut with a small sanding disk or a file. Hope this makes sense? If not let me know and I will try to clarify.

Bernie

[kaycee]

I use a 4 1/2" grinder with the regular cutoff wheel,do like they said above and take your time and use tape to guide you.I don't have a big enough compressor to run any thing so I just make do with what I got

[Kim57]

I use a 4-1/2 angle grinder and a tape line. If you go slow it is pretty easy to keep it on the line.
Kim

[bobinbc]

I like an air shears or plasma with a straight edge guide.

The shears not expensive, about $60 at Sears



The plasma is a bunch more....

[drivea55]

I use this awesome nibbler you can just put on your electric drill. I found it at one of the local home shows and was sold when watching the demo.

It has never let me down. Clamp a straight edge for it to follow and it just chews burr free thru it all.

here is a link to it. http://www.baddogtools.com/dotnetnuk...dDogBiter.aspx

what really sold me was the guy holding a 14g pc of s.s. and the drill in his other hand and ripping thru it with no biting, tugging and burr free...

Sorry for being long, but when I actually find a tool that is beyond its use i get excited...

FYI...

it cut my firewall right out free hand.

Brian

[Dan Bowles]

I've used both Bob and Bernie's techniques. Cut long, trim to the line. I have electric shears that I bought at HF but get ticked off when I break the blades!

[Russell Ashley]

Thanks everyone, all good advice. I think a 4 1/2 inch angle grinder would make it a lot better as my 3 inch doesn't give much room between it and the panel. That BadDog nibbler looks cool, but I don't want to divert that much money away from my patch panel fund right now. I think I'll see about getting a nibbler like BobinBC mentioned because I can use a straightedge with it.

[55metalmonkey]

I use a buch of different things, depends on what I need to cut.
4 1/2" cut off disc in my mini grinder for most things, 3" cut off in die grinder for the tight spaces, an air shear or nibbler for generaly flat long sheet metal and an air saw with a real fine blade for when all else fails. tape lines and taking your time help in getting a straight line but when possible I try to cut slightly off the tape line then grind to the tape line with a fine flapper disc.

[52 Rat]

I use a 90 degree die grinder with a very thin cut off wheel. I also use an air saw with a fine tooth blade. Remember, measure several times and allow a little for fit. I always leave a little material and grind it off.

[cajundragger]

i use a 1/4 horse straight cutoff wheel with 3.5" .030 wheels. make sure you cut with as much as the wheel pushed into the material as possible and change blades often. I can cut straight as a laser.

I think its more of technique. I used to be crappy, but Im way better now.

stay away from a saw for long cuts unless it is the only option and you use really tall blades so that the metal you've already cut guides the blade.

sometimes I use a straightedge clamped to the material and the plasma. This is by far the quickest and least heat input into the metal. But with a good cutoff I dont put much heat into it either.

[MrDude_1]

I havent done alot of bodywork, but when I have to cut long straight lines like that in sheetmetal that is mounted to something, i run a tape line first, then clamp a flat piece of steel next to the tape.
then i run my cutoff wheel down it, with the guard resting on my steel bar guide.
this gives me a fairly straight line.
i can then use a sanding disc on the grinder to finish it.

[Russell Ashley]

Update to my question: Thanks for the suggestions everyone. I bought a four inch air die grinder and some wheels that are specifically for cutting metal. The blade sits at a right angle to the body of the grinder and it has a handle that screws into either side. With the second handle and larger blade it's easy to control and I don't have any problem running a straight line with it. It's one of those tools I wish I'd bought a long time ago.

[solidaxel]

Body, frame, and running boards, all cut with a few new blabes on Sawzall