Cutting Steel w/ Dremels

[Indybird]

So I've been working on my current mod, AMGPC (http://www.thebestcasescenario.com/forum/showthread.php?t=15676), and I finally got a hold of a dremel from my friend to use instead of my jig-saw. So I open up the package of metal cut-off disks and pop one on.

I go to cut the case and get about 2" before the wheel is completely gone.

Am I missing something here? I'm sure all of you don't go through 20-30 disks during the course of a mod.

What speeds, techniques and/or disks do you guys use so that your not going through disks left and right?

Thanks,
Indybird

[TheGreatSatan]

You need reinforced Dremel blades. Buy the EZ (http://www.toolbarn.com/product/dremel/EZ456B/) lock blades and the mandrel that holds it. These blades can be replaced in a couple of seconds.

Also, if the metal is thick you can just scour the metal instead of cutting all the way through. Then bend it back and forth untill it snaps at the cut off line

[nevermind1534]

I hated how fast those heavy duty cutting wheels got used up.

[crazybillybob]

Also don't run the dremel full out. I find that for most of my work I never get above 5 unless I'm polishing. When you cutting don't put allot of down pressure on the tool, let the weight of the dremel do the cutting. Keep the blade lined up with the cut (straight both linearly and vertically) it's easy to bind the disks if you don't ... then they snap!. Like Satan Said, the Fiberglass reinforced are the best, EZ lock or not.
A few safety / tool life lengthening tips (I've killed my far share of dremels ! :) )
Always wear safety glasses /goggles when operating your Dremel, there cheap enough that I've bought a pair for each toolbox, and Dremel case so there's always a pair close! Those disks will take an eye out when they break!
Also if your cutting with the dremel for a long time (the unit becomes warm!) Stop cutting let it run for about 5mins (no load) then let it cool for about 10-15 mins. Get a drink, eat a snack, say hi to your wife/boyfriend/Girlfriend/husband/love interest/ parents/ etc) Trust me if you don't stop you'll be sending that dremel in for repair and they never work quite as well when they get back :redface::banana:

Some guys here use the dremel for everything, I like using the jig saw for metal. That said the Dremel and the jig saw work well together, each can do things the other can't!

Good Luck,
CrazyBillyBob

[Indybird]

You need reinforced Dremel blades. Buy the EZ (http://www.toolbarn.com/product/dremel/EZ456B/) lock blades and the mandrel that holds it. These blades can be replaced in a couple of seconds.
The question is; how often do they need to be replaced? (Inches, feet, cm, etc)

Also, if the metal is thick you can just scour the metal instead of cutting all the way through. Then bend it back and forth untill it snaps at the cut off line.
Do you think that will leave a clean cut? Or will I have to clean it up afterwards?



Also don't run the dremel full out. I find that for most of my work I never get above 5 unless I'm polishing. When you cutting don't put allot of down pressure on the tool, let the weight of the dremel do the cutting.
I tried using the weight of the dremel but it got absolutely no where; though it didnt kill the disk ;)

Keep the blade lined up with the cut (straight both linearly and vertically) it's easy to bind the disks if you don't ... then they snap!. Like Satan Said, the Fiberglass reinforced are the best, EZ lock or not.
A few safety / tool life lengthening tips (I've killed my far share of dremels ! :) )
Always wear safety glasses /goggles when operating your Dremel, there cheap enough that I've bought a pair for each toolbox, and Dremel case so there's always a pair close! Those disks will take an eye out when they break!
Also if your cutting with the dremel for a long time (the unit becomes warm!) Stop cutting let it run for about 5mins (no load) then let it cool for about 10-15 mins. Get a drink, eat a snack, say hi to your wife/boyfriend/Girlfriend/husband/love interest/ parents/ etc) Trust me if you don't stop you'll be sending that dremel in for repair and they never work quite as well when they get back :redface::banana:

Some guys here use the dremel for everything, I like using the jig saw for metal. That said the Dremel and the jig saw work well together, each can do things the other can't!
Up until I got the dremel I had been using a jig-saw. My main problem was that the blade was too deep. http://i8.photobucket.com/albums/a29/Indybird/399883_lg.jpg
I couldn't do any turns without it catching on the metal. Do you know where to get shorter/thinner blades?

Good Luck,
CrazyBillyBob

Thanks for all of the advice!

-Indybird

[TheGreatSatan]

My EZ blades usually last me a long time. I can easily cut out a couple side panel windows with one blade. If the metal you're cutting is thick, buy an angle grinder. That's what I had to do when I was cutting R2-D2's Weber BBQ grill head.

[crazybillybob]

I like the bosh Jig saw blades, they cost a bit more but they last longer then the other brands (I was very disappointed with the dewalt brand!)
When cutting curves Cut a shallower curve then you need, If say your cutting a window, the center is all "scrap" so make multiple shallow cuts from your waste area into the line of the panel. You can get some intricate cuts that way.
I always have to file into the line to make it perfect but you'll need to file no matter what you cut with.

With the dremel try cutting from right to left (the dremel shaft pointing away from your body) with light pressure set it to a 4 for speed, you should move the metal... and it will take a few minutes to cut it's a dremel not a plasma cutter!

CrazyBillyBob

[Indybird]

I like the bosh Jig saw blades, they cost a bit more but they last longer then the other brands (I was very disappointed with the dewalt brand!)
CrazyBillyBob

Do you know of any thinner jig-saw blades? My problem was the blades were too deep and couldn't do any tight turns.

Thanks,
Indybird

[crazybillybob]

Some of the Bosh blades are thinner then most.
I don't have the model # right here.