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Jim_Gruber said:
What I want to know is what you use to cut that 1/4 steel plate. I went through lots of blades in the jig saw just doing aluminum. I did put a metal cutting blade on the bandsaw. That would probably handle.
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4 1/2" grinder with the thinnest cutoff blade you can find (DeWalt .045"). Leave the pencil line and then take half of the line (to the exact measurement) at the stationary sanding disc. For the inside crrners I do a little touch up with a small air die grinder with a 60 grit 2" (rigid backed) sanding disc (Gator Grit).

Oh, and use a full face shield! For a while I was trying to get by with just large safety glasses or one of those shields that just covers your eyes...and has LOTS of little vent HOLES! Seems every other night I was trying to get the filings out of my eyes...had to let one rust overnight so I could see it good enough to get it out. Found the face shield at Harbor Freight (cheap) but everyone seems to have them (Northern, TSC, etc.).

Ray
 
Thanks Ray. Yes I do remember having the Angle Grinder involved as well. Angle Grinder, Bench Grinder, Drill Press. Lots of manual time consuming metal forming.
 
Thanks Ray. Yes I do remember having the Angle Grinder involved as well. Angle Grinder, Bench Grinder, Drill Press. Lots of manual time consuming metal forming.
 
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