Metal Cutting - Best Way?

[wettrthebettr]

Got myself into a DIY project involving some Strut (e.g., Unistrut, Super Strut, etc.) and some steel angles. All of them need to be cut to length and I'd like the cuts to be clean when done (I know I can file/grind them).

So, how do I cut them? I don't want to hacksaw them. I have a right angle grinder but I haven't tried using it to make clean cuts before. I also have a Compound Miter Saw (12") but not sure about using it and what blades - also read I may need to slow the saw's blade speed down with a device.

we use a Portable Plasma Cutter at our Caltrans barn (shop) . It comes in handy for tight spots, can cut any pattern you want.
https://weldinghelmetpros.com/ramsond-cut-50dy-portable-plasma-cutter-review

 

[WhatExit?]

I was only looking at strut being the two cross bars. I made a sliding bed divider for my Raptor and used Stainless Strut --- now that shit was hard
Good info in this thread, in the field we used porta-bands or large cut-off saws if were doing a lot of cuts. But alas I'm retired and all the big-boy-cool tools are gone.
So for me it's hacksaw or sawzall these days for my home projects.

Can you post pics and info on what you did in your Raptor? I'd like to see that!

 

[WhatExit?]

One of the tools I use a lot is a SWAG Portaband saw table. They make a good tool a great tool. They make other neat stuff also.

https://www.swagoffroad.com/SWAG-Portaband-Tables-Accessories_c_35.html

Very cool tool...

 

[Taboma]

Can you post pics and info on what you did in your Raptor? I'd like to see that!

Sure I'll take a couple of pics when I head downstairs a bit later --- for now I'll give you "How it all began" story and some major components.
In 2004 needing a new work truck and having driven Fords and Chevys forever, decided to purchase a new to the market Nissan Titan. Despite having some 1st year teething issues, the damn thing was fun to drive and pretty ballsy for the time.
The one thing I really came to appreciate was Nissan's Utili-Track bed system. Great for securing tie downs where ever you wanted, but most of all they had a bed divider that slid fore and aft on side rails. Since I was always hauling electrical supplies to my field crews when I'd visit the jobs, this way they weren't sliding around and were secure.
First thing I noticed was how the rails resembled Uni-Strut, in fact even the dimensions were almost the same --- Hmmmm Strut spring nuts worked just fine in it, so I could create custom hold-ems and brackets and such things using strut components and spring nuts --- cool as hell.

One thing, that Titan bed divider is all aluminum, looks heavy but in truth it's very strong, but extremely light, it's been securing my truck loads for 15 years and is holding up strong. I'm not sure if the one Nissan sells for the Frontier is the same dimensions as the Titan one, even though the rails look similar. I see the dividers for sale online for around $ 200. They've changed the look of the divider, but I think the track itself is still compatible with Strut.

Long story shorter --- I liked that Titan sliding bed divider so much I've re-installed it in three other trucks since then. It actually fit the GMC track in my Sierra Denali, but when I moved to Ford, their track system sucked, so I made the track out of the Stainless Strut. Moving from the 15' F150 Platinum to the Raptor required a different way to mount it. So the strut mounting method will vary truck to truck and even by the year. Here's a few pics off the net to show what I'm talking about.

Nissan's Track --- notice the strut spring nuts, others have caught on to just how versatile their system is. I'll post up a couple of pics of mine a bit later.

This is the older style divider which mine is ---- just imagine the rails being strut -- although I've only got the side rails that I need for the divider.

Here's the new style, but you can see the side pieces that secure it in the strut and allow it to slide. I've had to make some slight modifications over the years to accommodate different bed widths.

 

[Happy Smitty]

I've been fabricating as a hobby for a long time. Learn to use these tools and you can make just about anything in your garage.

 

[KMH]

View attachment 838699

LOL, this is what it really looks like.

 

[WhatExit?]

View attachment 838840 LOL, this is what it really looks like.

Eeesh! An advance warning especially before breakfast woulda been good

 

[WhatExit?]

Sure I'll take a couple of pics when I head downstairs a bit later --- for now I'll give you "How it all began" story and some major components.
In 2004 needing a new work truck and having driven Fords and Chevys forever, decided to purchase a new to the market Nissan Titan. Despite having some 1st year teething issues, the damn thing was fun to drive and pretty ballsy for the time.
The one thing I really came to appreciate was Nissan's Utili-Track bed system. Great for securing tie downs where ever you wanted, but most of all they had a bed divider that slid fore and aft on side rails. Since I was always hauling electrical supplies to my field crews when I'd visit the jobs, this way they weren't sliding around and were secure.
First thing I noticed was how the rails resembled Uni-Strut, in fact even the dimensions were almost the same --- Hmmmm Strut spring nuts worked just fine in it, so I could create custom hold-ems and brackets and such things using strut components and spring nuts --- cool as hell.

One thing, that Titan bed divider is all aluminum, looks heavy but in truth it's very strong, but extremely light, it's been securing my truck loads for 15 years and is holding up strong. I'm not sure if the one Nissan sells for the Frontier is the same dimensions as the Titan one, even though the rails look similar. I see the dividers for sale online for around $ 200. They've changed the look of the divider, but I think the track itself is still compatible with Strut.

Long story shorter --- I liked that Titan sliding bed divider so much I've re-installed it in three other trucks since then. It actually fit the GMC track in my Sierra Denali, but when I moved to Ford, their track system sucked, so I made the track out of the Stainless Strut. Moving from the 15' F150 Platinum to the Raptor required a different way to mount it. So the strut mounting method will vary truck to truck and even by the year. Here's a few pics off the net to show what I'm talking about.

Nissan's Track --- notice the strut spring nuts, others have caught on to just how versatile their system is. I'll post up a couple of pics of mine a bit later.
View attachment 838817

This is the older style divider which mine is ---- just imagine the rails being strut -- although I've only got the side rails that I need for the divider.
View attachment 838818

Here's the new style, but you can see the side pieces that secure it in the strut and allow it to slide. I've had to make some slight modifications over the years to accommodate different bed widths.
View attachment 838819
View attachment 838820

Thanks! So you made this rail and it's stainless steel? How'd you cut the half-round "notches" in the rails?

And you made this from scratch? (well, from metal but designed and built it?)

 

[WhatExit?]

The racks I'm going to be making are for my Jeep Gladiator. It has the Jeep Trail Rail System (pic below) which is almost identical to the Toyota Tacoma Bed Rail system which is good because there's so much hardware available for them and many Taco owners have done some cool DIY. There are also Molle panels available that attach to the Track Rails and the bed covers and caps typically attach to the vehicle using the Trail Rails which I like much better than the clamps or drilling holes in the tops of the bed sides often used.

 

[Taboma]

Wow that Gladiator track looks almost identical to the Nissan system. Is it dimensionally the same as Strut, like Nissan's ?

I didn't build the aluminum divider, it's the one I kept from my 04' Titan --- I've only continued to modify the track and mounting methods so I could use it on so many different trucks.

I didn't cut any notches, they're not necessary or used for the sliding divider, those were just to lock in the tie-down cleats. The divider is locked in place by tension on those slides when you tighten the knobs.

Be curious to see how well the Strut spring nuts work in your Jeep rail, using those you can mount tons of hold-downs, brackets and I've seen guys use the Strut conduit straps to mount pvc fishing rod holders.

 

[WYRD]

View attachment 838840 LOL, this is what it really looks like.

All jokes aside, that sucks but at least you are alive to tell the story

 

[WhatExit?]

Wow that Gladiator track looks almost identical to the Nissan system. Is it dimensionally the same as Strut, like Nissan's ?

I didn't build the aluminum divider, it's the one I kept from my 04' Titan --- I've only continued to modify the track and mounting methods so I could use it on so many different trucks.

I didn't cut any notches, they're not necessary or used for the sliding divider, those were just to lock in the tie-down cleats. The divider is locked in place by tension on those slides when you tighten the knobs.

Be curious to see how well the Strut spring nuts work in your Jeep rail, using those you can mount tons of hold-downs, brackets and I've seen guys use the Strut conduit straps to mount pvc fishing rod holders.

The Trail Rail is about the same as the Toyota Tacoma Bed Rail system. I don't know about the Nissan system. I think the tracks are close to strut but not quite as wide as I've seen posts where people say the spring nuts won't quite turn vertical so they use them on an angle. Instead, there are many T-Slot Nuts available

Here's what I'm using:
MISSION AUTOMOTIVE 5-Pack of T-Slot Nuts - Ideal T Slot Nut for Toyota Tunda & Toyota Tacoma Pick-Up Truck Bed Deck Rails - Cleat/Cleats
https://www.amazon.com/gp/product/B07739WXJB/ref=ox_sc_act_title_1?smid=A18UZ8OJII3VEM&psc=1

 

[Taboma]

The Trail Rail is about the same as the Toyota Tacoma Bed Rail system. I don't know about the Nissan system. I think the tracks are close to strut but not quite as wide as I've seen posts where people say the spring nuts won't quite turn vertical so they use them on an angle. Instead, there are many T-Slot Nuts available

Here's what I'm using:
MISSION AUTOMOTIVE 5-Pack of T-Slot Nuts - Ideal T Slot Nut for Toyota Tunda & Toyota Tacoma Pick-Up Truck Bed Deck Rails - Cleat/Cleats
https://www.amazon.com/gp/product/B07739WXJB/ref=ox_sc_act_title_1?smid=A18UZ8OJII3VEM&psc=1

Being in the business I always had a supply of strut spring nuts from 1/4 thru 1/2", I just ground a bit off two corners. Those T-Slots look plenty substantial.

 

[BHC Vic]

This is what I use in my shop

 

[BHC Vic]

Doing some fab work on the trailer today. Cutting some practice pieces before I I take my one shot. Little gate action and somewhere to tie down to.

 

[D19]

Metal chop saw. I have a ridgid but if only a few cuts harbor freight. View attachment 838475

That one is a good deal. I recently bought one to cut up a bunch of braided hose. Even better deal with the 20% off coupon you can get online.

 

[River Dirt 2]

Or you can just buy the materials...

L-Track (VersaTie)

L-Track (VersaTie)

www.macscustomtiedowns.com

 

[highvoltagehands]

Being in the business I always had a supply of strut spring nuts from 1/4 thru 1/2", I just ground a bit off two corners. Those T-Slots look plenty substantial.

I hear you Taboma. It’s kinda hard to go out and buy OEM when you have unlimited access to unlimited types of unistrut channel and hardware. Myself, I prefer using the shallower 7/8“ unistrut channel with eye bolts and channel cone nuts for cargo rails, instead of the deeper 1-5/8” and spring nuts. But when higher strength rating is needed, deep strut is nice.

 

[WhatExit?]

I hear you Taboma. It’s kinda hard to go out and buy OEM when you have unlimited access to unlimited types of unistrut channel and hardware. Myself, I prefer using the shallower 7/8“ unistrut channel with eye bolts and channel cone nuts for cargo rails, instead of the deeper 1-5/8” and spring nuts. But when higher strength rating is needed, deep strut is nice.
View attachment 886924 View attachment 886927

"unlimited access to unlimited types of unistrut channel and hardware" - where is this place you speak ofDo I need a membership?

 

[highvoltagehands]

In the electrical trades we use Unistrut materials for mounting, fastening, securing....just about anything and everything. You can usually find some laying around on just about every commercial/industrial project.

 

[Icky]

In the electrical trades we use Unistrut materials for mounting, fastening, securing....just about anything and everything. You can usually find some laying around on just about every commercial/industrial project.

Usually with sharp edges and burrs because electricians were never taught to deburr in apprenticeship school

 

[highvoltagehands]

You got that right Icky. And if a guy had to use a hacksaw, you can bet only the rails were cut with saw, and the remaining strut was bent back and forth until broken in two....or so I’ve been told.

 

[bilz]

Any one use the Evolution Rage 2 saw?