Metal Cutting Bandsaw vs Angle Grinder

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belfastrab

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Oct 27, 2016
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Hi Guys

I make a couple of knives a month as a hobby and give them away to friends and family I just enjoy the making process so not someone who is making knives daily or even weekly.

I have until now just used an angle grinder to roughly cut out my knife blanks from ground flat bar and then grind to the line on the bench belt grinder and that is working out ok. However I have been wanting to pull the trigger as it were on one of these portable metal cutting bandsaws for a few months but trying to justify the cost for doing the same job as my angle grinder.

I see that a lot of North Americans have the cheap and cheerful Harbor Freight models and they look like they work well once a table has been fabricated for them and if I could get one as cheap as those in the UK I would already have one but the problem is there is only three manufacturers that sell these types of bandsaws in the UK and they are Dewalt, Makita and Milwaukee all great brands but also fairly expensive for what I see as a luxury. So pretty much they are all working our at around $300 US... it's not that I can't afford one but on the same hand don't like wasting money just for the sake of it.

So the way I see it is that it will be much easier, cleaner and faster to use a bandsaw for cutting blanks plus it looks like you can get a lot closer to the line that what an angle grinder allows so less grinding on the belt grinder but do you think that the speed and easier operation is worth $300?

I am primarily a wood worker and knives has been my first time playing with metal as a material and I do enjoy working with it and trying to teach myself brazing as the moment so I can see a lot more projects going down the metal route in addition to the knives but again any project I can envision can be quickly cut out with an angle grinder... so apart from what is already mentioned and the thrill of buying a new tool (and hiding it from the wife) is there any benefits over a metal cutting bandsaw as opposed to the much cheaper angle grinder for the light user?

Don't get me wrong I want the tool but there is a list of other tools I want too so just trying to prioritize.

Thanks for any words of wisdom / experience on the matter.

Cheers

Rab
 
I think you'll be happy you got the bandsaw (called "Porta-band" over here) - not only will it be good for cutting blade to profile, you'll also use it more than you imagine for other metal (and even wood) projects. You will wish to rig up a table for it and make it like a "table saw" type thing. Any of those 3 brands you named will be good - I've got the Milwaukee and am quite happy with it.

Good luck and have fun,

Ken H>
 
What ken said.
A port-a-band and a SWAG table will work very well for anyone but a full time shop. Search the many threads on port-a-band saws and SWAG tables for lots of comparisons and examples.
To make the cutting better and the blades last longer, the Lenox bi-metal blades are well worth their cost.
 
It may be a hefty investment, but I sincerely doubt you will regret it once you start using it, especially compared to a cut-off wheel/angle grinder set up.
I'm not familiar with the UK market, but maybe keep an eye out in the classifieds, ebay, craigslist, etc... and see if you can score a used one for cheaper.
 
Yea, what Stacy says "SWAG table" - I could not remember the name of the table. It's also not that hard to rig something up that works for less money.
 
Be sure to get bi-metallic blades for the porta-band... a must have for cutting metal
 
Keeps your piece cool. No shower of sparks. You can rig it to a foot switch. Much much safer.
I also use it to trim scales, among other things. I don't think you would regret the purchase. I bought the miluakee and love it.
 
Harbor freight ships international.. Not sure of the rate, but it might be worth the effort.. Check their FAQ and customer service..

Sent from my HTC 10 using Tapatalk
 
Check out pawn shops too, I found a dewalt heavy duty port-a-band for 120$ a month or so back...


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Tables are easy to make for the portabands, you can search for some very cool ways they are mounted.

An angle grinder is very dirty, not precise, heats up the piece and kinda dangerous. Metal cuttin bandsaws are more than worth their cost, you won't be throwing away as much materials as with an angle grinder.

Another alternative is to get a cheap horizontal/vertical and set it up vertical with the table it comes with, reinforce the legs and I made a seat in my so I can sit on it. They are actually cheaper than the portaband setups. I have both and will use that when I have a cut that is too deep for my deep throat Milwaukee porta.

The last option is a jigsaw with a bimetal blade, I would use a jigsaw way over an angle grinder.
 
I have the Dewalt variable speed with the SWAG table. What I did not anticipate when I first got this set up (and I'm on my second Dewalt saw after thousands of knives, I am a full time shop), is how many other jobs I would use this saw for. I'd originally intenede to get the "Swag table that goes into a vise. My intent was to us the saw to cut out blades and then put saw and table away when not in use. I decided not to get that table but to get the one set up full time. Good decision, I use that little saw for so many things. Cutting pins, trimming handle materials, cutting bolster material, opening steel packages from Aldo and the list goes on and on. GET THE SAW!
 
The SWAG table is worth the money and makes a great space saving way to cut almost anything knife related. They make a model for the most excellent Dewalt and Milwaukee brand portabands. Make sure to buy the "deep throat model" of Dewalt or Milwaukee portaband before you choose the SWAG table model. I think those models have about a five inch opening and it is important to get as large an opening as possible in my opinion. I was using mine yesterday and just barely was able to cut the piece I was working on. Also, having a good 4 1/2 inch angle grinder is very handy too for fast straight cuts and cutting blanks of 6 foot pieces of steel stock. Some knife makers are afraid of angle grinders but just wear a leather apron, eye, and ear protection and only make straight cuts and you will do fine. Where I live (in Bakersfield) there are guys who use angle grinders every day in the oilfields for year after year with no injuries because they are careful. Buffers are more scary to me. Just my opinion. Larry
 
Folks talk about an angle grinder being dangerous, and they are, even the little 4" job can sure cut some meat if not careful. BUT - if you wish to feel a "real" tool, use one of the big 9" side grinders. Now, those things you have to be really careful with. Just the wheel spinning must be held steady so they don't "get away" from you. They are a real "two handed" tool.

Ken H>
 
The ONLY thing I've got to add is that the grinding wheel "heats" up the cutting surface and depending on how you deal with that can cause some problems. I bought a Dewalt porta bandsaw. Mounted it with a small work surface table and along with Lennox blades NEVER looked back. Your mileage may vary!
 
Found this thread in a search. I've been looking for a band saw for metal. I have a Jet 14" wood cutting band saw that I'm debating on converting to use on metal. It would appear that swapping the motor with a 1 HP 3 phase (currently has a 1HP single phase) and a VFD would slow it down in order to use it on metal. There's a few YouTube videos of folks that have done this, but it doesn't seem very common and I'm wondering why. Will I lose torque at lower speeds?

Anyone see a good reason to avoid doing this? My other option is a portaband type saw with the Swag table. I figured by the time I bought the portaband and the table, the cost for the motor and VFD would be about the same. Am I missing something? Anyone here done this or have an opinion?

Thanks.
 
It's doable but with just a vfd it's hard to slow them down enough and maintain the necessary torque. Generally you will need to swap some pulleys in addition to adding the vfd.
 
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