Wood/Glass/Metal Which best metal cutting tool to do this job?

[tirelessphoenix]

TL;DR Summary

I want to do a straight metal cutting

I want to do a straight metal cutting, leaving a not too wide line whole in the middle (the filled white part) as seen in the picture. Does anyone know which tool would do this best?

 

[jedishrfu]

Would a Dremel tool work with a cutting disk?

https://www.amazon.com/Dremel-4000-4-34-Variable-Rotary/dp/B00LUU2XFO/?tag=pfamazon01-20

The Dremel in the picture has a cutting disk attached.

It would be a manually intensive job and likely not as straight as you might want it.

I've used a Dremel tool to cut off a hose fitting on my outside faucet that got stuck over time.

 

[Flyboy]

Second the Dremel call. Take your time, let the speed of the tool do the work. Use either a rotary file on the Dremel and/or needle file(s) to clean up.

Unless you have access to a milling machine, the Dremel will be pretty much the fastest possible solution.

 

[jrmichler]

If you are cutting steel, and can tolerate a 2.5 mm kerf, a steel cutting blade in a table saw works very well. This particular blade has cut over 30 lineal feet of steel in various thicknesses up to about 3/8" in my table saw. Goggles for eye protection are required because hot chips fly. I clean the sawdust from inside my table saw before using because I do not want the hot chips starting a fire. Hearing protection also required because it's noisy.

 

[berkeman]

I clean the sawdust from inside my table saw before using because I do not want the hot chips starting a fire.

Great tip! I don't know if I would have thought of that ahead of time (versus when I was reaching for the fire extinguisher)...

 

[Flyboy]

If you are cutting steel, and can tolerate a 2.5 mm kerf, a steel cutting blade in a table saw works very well. This particular blade has cut over 30 lineal feet of steel in various thicknesses up to about 3/8" in my table saw. Goggles for eye protection are required because hot chips fly. I clean the sawdust from inside my table saw before using because I do not want the hot chips starting a fire. Hearing protection also required because it's noisy.
View attachment 351716

The issue I see is that he’s looking at a plunge cut in the middle of the piece, not a cut that can be made from the end of the piece. It also seems to be a tube/box section, not plate, and it’s unclear if the cut is intended for both sides.

@tirelessphoenix , can you show us another view of the piece that you wish to cut this slot into? Some dimensions will be quite helpful as well.

 

[tirelessphoenix]

here it is. its a hollow square, not that thick

 

[gmax137]

Chain drill then file. This will be tedious because the tube steel limits the file stroke. Take your time and drill carefully to avoid a wiggly slot. A dremel tool is faster than filing but it also makes faster mistakes if you're not well practiced.

Maybe there is a "maker" space nearby? They could mill your slot in 10 minutes.

 

[sophiecentaur]

I may be preaching to the converted but I have to mention the importance of firm workpiece holding (clamping) if you want to avoid 'wandering' of the cut and juddering. I really don't believe the YouTube videos where the guy does everything freehand and gets a perfect line and finish. I always suspect that there's a milling machine lurking somewhere in behind.

High speed and a fine tool will improve chances of a convincing finish.