Jerry
Jerry PowerDork
1/7/25 1:01 p.m.

I bought a length of 3/16" steel bar at Menards recently.  I plan to use it to make simple brackets for Hella driving lights on the GR Corolla.  Someone else on a forum made something similar and shared fairly detailed photos, looks like I'll be able to attach to the radiator support behind the grill.

He used 1/8" and doubled up to minimize vibrations, I was Mr Smart and bought 3/16" instead.  Now I'm wondering the best way to cut without a garage full of tools.  I have a simple hacksaw (Google says that's probably best) and a Dremel.  I have access to a bench grinder at work to clean any edges, and a drill press if I am not successful with my cordless drill.

Should I go with the hacksaw, or would the Dremel be a good choice?  I have only used it for a few minor things so far, so not full up on how many attachments it has.  (I only need to make two cuts.)

Mr_Asa
Mr_Asa MegaDork
1/7/25 1:10 p.m.

Of those two, I would use the hacksaw.  With a fresh blade it will take the same amount of time as futzing with all the broken blades and weird angles the Dremel will give you 

If you have a 5" angle grinder you could also use a cut-off wheel.

NOHOME
NOHOME MegaDork
1/7/25 1:12 p.m.

Hacksaw is the correct answer.

In my version of reality, the job can not be done without a cut-off saw. laugh

carbidetooth
carbidetooth Reader
1/7/25 1:14 p.m.

A good hacksaw will put a lot of tension on a good blade. A Ho-hum hacksaw will wander and frustrate.

If you're looking to add to tool arsenal, I might suggest an angle grinder. Cut off disc, flap wheel, wire wheel, and all manner of other accessories will come in handy for this job and probably others. Cover your eyes, though. These handy little buggers throw all sorts of debris at your face.

WonkoTheSane
WonkoTheSane GRM+ Memberand UberDork
1/7/25 1:32 p.m.

Totally agreed with CarbideTooth.   My wife jokes that every job I do involves the angle grinder somehow, they're my favorite multipurpose destructive tool. 

 

With what you have at your disposal, yeah, probably hack saw.  How wide is the bar?  it might be tedious to do with the hacksaw, but the problem with a dremel (as mentioned), is that they don't really have enough overhang at the cutting disc, so you end up slicing something like that at an angle, not a square cut.

jharry3
jharry3 GRM+ Memberand Dork
1/7/25 2:03 p.m.

A Sawzall with a metal cutting blade works also.   I recently used mine on similar material.

Jerry
Jerry PowerDork
1/7/25 2:22 p.m.

In reply to WonkoTheSane :

It's only 1" wide, which is why I went into this thinking maybe the Dremel would work "enough".  If I cut at both ends of the bar, any sloppiness could be hidden behind the grill.

Might look into an angle grinder, Oh no another trip to Menards for toys...  (I remember using one at an old contractor job now, we fixed leaking pipes and stuff while leaking, and sometimes had to grind off tabs and other bits to put a clamp over the leak.)

EDIT:  are they really only $15??  Hell, why not.

Tool Shop® 4.3-Amp Corded 4-1/2" Slide Switch Angle Grinder

Tom Suddard
Tom Suddard GRM+ Memberand Publisher
1/7/25 2:25 p.m.

Hacksaw is going to be your answer, but this is a great excuse to go buy an angle grinder....

I built a few cars with this before buying a better one:

https://www.amazon.com/BLACK-DECKER-Grinder-6-5-Amp-BDEG400/dp/B00RZV20CS/ref=sr_1_5

Motojunky
Motojunky Reader
1/7/25 2:51 p.m.

Another vote for an angle grinder. I bought a $15 Harbor Freight angle grinder ~25 years ago (mail order) hoping that it would last a few years. It still works! I have bought a couple of others in more recent years so that I'm not constantly switching between cutting disk, grinding disk, flapdisk, and wire wheel. One of these days I'm going to spring for a nice cordless one as well. 

EDIT: Don't forget the eye protection. I use a face shield when using the cutting disk. 

SkinnyG
SkinnyG PowerDork
1/7/25 7:56 p.m.

I have five angle grinders, because I hate changing the cutters on them.

Grinding disk

Cutting disk

Sanding disk

Wire Wheel

Shrinking Disk (for true sheet metal snobbery)

But to answer your question - I, too, would use the hack saw.  I buy Starrett blades.

NOHOME
NOHOME MegaDork
1/7/25 8:03 p.m.

This thread would have been better if the OP had posted that he had no cutting tools and no $$$.

Tom Suddard
Tom Suddard GRM+ Memberand Publisher
1/7/25 9:56 p.m.

Wait, OP has GR Corolla money... get a laser!!!!

Mr_Asa
Mr_Asa MegaDork
1/7/25 9:58 p.m.
SkinnyG said:

I have five angle grinders, because I hate changing the cutters on them.

Grinding disk

Cutting disk

Sanding disk

Wire Wheel

Shrinking Disk (for true sheet metal snobbery)

But to answer your question - I, too, would use the hack saw.  I buy Starrett blades.

I'm not quite there yet, but I'm getting ready for it

brandonsmash
brandonsmash GRM+ Memberand HalfDork
1/7/25 10:49 p.m.

At least go with an angle grinder. They're incredibly useful in general. 

 

NOHOME
NOHOME MegaDork
1/7/25 11:06 p.m.
Mr_Asa said:
SkinnyG said:

I have five angle grinders, because I hate changing the cutters on them.

Grinding disk

Cutting disk

Sanding disk

Wire Wheel

Shrinking Disk (for true sheet metal snobbery)

But to answer your question - I, too, would use the hack saw.  I buy Starrett blades.

I'm not quite there yet, but I'm getting ready for it

Shrinking disc is amazing. But be warned that when first learning to use you can end up feeling like the sorcerer's apprentice. The thing is more art than science. Also the most scary tool in the arsenal.

WonkoTheSane
WonkoTheSane GRM+ Memberand UberDork
1/7/25 11:49 p.m.

TIL about shrinking discs!   Neat!

Jerry
Jerry PowerDork
1/8/25 8:34 a.m.
Tom Suddard said:

Wait, OP has GR Corolla money... get a laser!!!!

Maybe a laser sword would work?

RevRico
RevRico GRM+ Memberand MegaDork
1/8/25 8:37 a.m.

Sounds like the perfect excuse to buy a plasma cutter to me. They're cheaper now than ever before. 

My order would be plasma, angle grinder, sawxall, hacksaw. 

Mr_Asa
Mr_Asa MegaDork
1/8/25 9:37 a.m.

An additional thought on multiple angle grinders.

If you are welding multiple materials frequently, I would suggest getting a dedicated grinder for each.  Prevents contamination, especially with Aluminum 

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