# Best way to cut 1-3/8 in. Zinc Steel Flat Bar 1/16 in. Thick? **URL:** \ **Category:** Factual Questions\ **Created:** [May 27, 2015, 12:39am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926 "2015-05-27T00:39:59Z")\ **Posts on this page:** 20\ **Page:** 1
**Author:** ![Mangosteen](https://avatars.discourse-cdn.com/v4/letter/m/6a8cbe/32.png) [@Mangosteen](https://boards.straightdope.com/u/Mangosteen)\ **Post date:** [May 27, 2015, 12:39am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/1 "2015-05-27T00:39:59Z")
What is the best and most economical way to cut a piece of 1-3/8 in. x 36 in. Zinc Steel Flat Bar 1/16 in. Thick? I need to cut several in half. Thanks! ---
**Author:** ![GaryM](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/garym/32/241_2.png) [@GaryM](https://boards.straightdope.com/u/GaryM)\ **Post date:** [May 27, 2015, 12:42am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/2 "2015-05-27T00:42:23Z")
Band saw or portable band saw. I bought a Harbor Freight portable unit for occasional use and it’s fine. I did buy good bands though. ---
**Author:** ![MikeG](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/mikeg/32/4329_2.png) [@MikeG](https://boards.straightdope.com/u/MikeG)\ **Post date:** [May 27, 2015, 12:51am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/3 "2015-05-27T00:51:38Z")
Angle grinder would do the trick as well as being more versatile. ---
**Author:** ![Xema](https://avatars.discourse-cdn.com/v4/letter/x/9de053/32.png) [@Xema](https://boards.straightdope.com/u/Xema)\ **Post date:** [May 27, 2015, 12:53am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/4 "2015-05-27T00:53:02Z")
A decent hacksaw should have no problem with cuts like that. Or, for better speed, use a Sawzall. ---
**Author:** ![GaryM](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/garym/32/241_2.png) [@GaryM](https://boards.straightdope.com/u/GaryM)\ **Post date:** [May 27, 2015, 1:02am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/5 "2015-05-27T01:02:51Z")
> [@MikeG](#): > > Angle grinder would do the trick as well as being more versatile. More versatile perhaps, but a better chance of burning the zinc which is not good for your lungs. ---
**Author:** ![Joey\_P](https://avatars.discourse-cdn.com/v4/letter/j/919ad9/32.png) [@Joey\_P](https://boards.straightdope.com/u/Joey_P)\ **Post date:** [May 27, 2015, 1:04am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/6 "2015-05-27T01:04:49Z")
1-3/8" as in almost an inch and half thick and 3 feet across. That’s an awful lot of metal for a hacksaw. How precise does this cut need to be and how often do you need to do it. If it needs to be pretty close and and not that often, IMO, your best bet is to call up a machine shop and have them do it for you. ETA, I totally read that wrong. Yeah, hack saw, sazall, I wouldn’t be surprised if a heavy duty wire/diagonal cutter could make it through them, but it would be messy and leave sharp edges. Personally, I’d probably use my angle grinder, that was $50 very well spent. Someone mentioned the fumes, if that’s an issue, you could take the project outside. ETA2, if you do use a hacksaw, it’ll probably be much easier to clamp a bunch of them together. That should cut down on the vibration. ---
**Author:** ![FluffyBob](https://avatars.discourse-cdn.com/v4/letter/f/ecb155/32.png) [@FluffyBob](https://boards.straightdope.com/u/FluffyBob)\ **Post date:** [May 27, 2015, 1:20am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/7 "2015-05-27T01:20:35Z")
I work with wood much more than metal, but I can’t see how you could possibly cut a 1/16" slice of something with as crude a tool as a Sawzall or grinder. And a grinder is going to burn something a lot thicker than 1/16". Maybe a hacksaw but that sounds tedious if you want more than one slice. I would definitely make a jig if I was to try this and I am still not sure if you could get a clean cut. The band saw sounds plausible, but I still think you would need a jig to slide it through smoothly. I am betting burning would be an issue still. A lubricated blade would probably be best for cutting something so thin. I am interested to see what our resident metal workers have to say. ETA OK confusion here - is the material 1/16" thick or is it being cut into 1/16" slices? ---
**Author:** ![Nefario](https://avatars.discourse-cdn.com/v4/letter/n/59ef9b/32.png) [@Nefario](https://boards.straightdope.com/u/Nefario)\ **Post date:** [May 27, 2015, 1:26am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/8 "2015-05-27T01:26:43Z")
- hacksaw, fine tooth blade (less than 1/16 pitch) - Whatever you use, the job will be much easier if you can clamp the metal down to a rigid object - workbench, edge of table, hold in a vise, etc. ---
**Author:** ![boytyperanma](https://avatars.discourse-cdn.com/v4/letter/b/4491bb/32.png) [@boytyperanma](https://boards.straightdope.com/u/boytyperanma)\ **Post date:** [May 27, 2015, 1:50am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/9 "2015-05-27T01:50:01Z")
If there is a welding shop and/or fabrication shop anywhere near you can can ask them to cut it. Your project would be done with a hydraulic break and take about 30 seconds for set up cut. Guaranteed a perfectly square cut. The shop I use charges a minimum cutting fee of 20 bucks. Which is what I usually pay. Most often I have them cut well casing and I-beams which are done on an industrial band saw. If I need 1/4 steal plates they cut them to size on the break. I just pay for the steal then rather then the cutting fee, which is usually cheaper than the cutting fee. I’ve suggested they reevaluate their fee structure… ---
**Author:** ![jimbuff314](https://avatars.discourse-cdn.com/v4/letter/j/c57346/32.png) [@jimbuff314](https://boards.straightdope.com/u/jimbuff314)\ **Post date:** [May 27, 2015, 1:59am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/10 "2015-05-27T01:59:02Z")
> [@FluffyBob](#): > > […] ETA OK confusion here - is the material 1/16" thick or is it being cut into 1/16" slices? Says 1/16 inch thick twice. I take that to mean the bar is that thick. ---
**Author:** ![Dr.Strangelove](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/dr.strangelove/32/6613_2.png) [@Dr.Strangelove](https://boards.straightdope.com/u/Dr.Strangelove)\ **Post date:** [May 27, 2015, 2:01am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/11 "2015-05-27T02:01:31Z")
Waterjet. Clamp 'em all together on their edge (so they’re 1 3/8" tall) and let it rip. 5 seconds later you have a perfectly clean edge with zero heat distortion. You did say _best_… (you can’t have best _and_ most economical, so I picked one). ---
**Author:** ![Joey\_P](https://avatars.discourse-cdn.com/v4/letter/j/919ad9/32.png) [@Joey\_P](https://boards.straightdope.com/u/Joey_P)\ **Post date:** [May 27, 2015, 2:08am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/12 "2015-05-27T02:08:12Z")
> [@Dr.Strangelove](#): > > Waterjet. Clamp 'em all together on their edge (so they’re 1 3/8" tall) and let it rip. 5 seconds later you have a perfectly clean edge with zero heat distortion. > > You did say _best_… (you can’t have best _and_ most economical, so I picked one). In that case, my first suggestion was also going to be to take them to a place with a plasma or laser cutter. Second was going to be to find not just a machine shop, but a machine shop with a CNC machine. ---
**Author:** ![Ornery\_Bob](https://avatars.discourse-cdn.com/v4/letter/o/da6949/32.png) [@Ornery\_Bob](https://boards.straightdope.com/u/Ornery_Bob)\ **Post date:** [May 27, 2015, 2:12am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/13 "2015-05-27T02:12:30Z")
There’s a junior college with a metal shop not far from where I live and I’ve taken small jobs there and asked for help. I usually say I’m an art student and need help on a project. Otherwise, I’d vote hacksaw as well. ---
**Author:** ![jasg](https://avatars.discourse-cdn.com/v4/letter/j/f0a364/32.png) [@jasg](https://boards.straightdope.com/u/jasg)\ **Post date:** [May 27, 2015, 2:51am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/14 "2015-05-27T02:51:34Z")
> [@Mangosteen](#): > > What is the best and most economical way to cut a piece of 1-3/8 in. x 36 in. Zinc Steel Flat Bar 1/16 in. Thick? > > I need to cut several in half. > > Thanks! Half how? 2 pcs 18" long 2 pcs 1/32" thick 2 pcs 11/16" wide ---
**Author:** ![Chefguy](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/chefguy/32/138_2.png) [@Chefguy](https://boards.straightdope.com/u/Chefguy)\ **Post date:** [May 27, 2015, 3:23am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/15 "2015-05-27T03:23:27Z")
You could probably also use a jigsaw with a metal-cutting blade, as 1/16" is not all that thick. ---
**Author:** ![Mangosteen](https://avatars.discourse-cdn.com/v4/letter/m/6a8cbe/32.png) [@Mangosteen](https://boards.straightdope.com/u/Mangosteen)\ **Post date:** [May 27, 2015, 3:23am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/16 "2015-05-27T03:23:47Z")
> [@jasg](#): > > Half how? > > 2 pcs 18" long > 2 pcs 1/32" thick > 2 pcs 11/16" wide Sorry, should have been more clear. Two pieces 18 inches long each. ---
**Author:** ![FluffyBob](https://avatars.discourse-cdn.com/v4/letter/f/ecb155/32.png) [@FluffyBob](https://boards.straightdope.com/u/FluffyBob)\ **Post date:** [May 27, 2015, 4:08am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/17 "2015-05-27T04:08:51Z")
Ok I get it now. 1/16" is pretty thin, of the tools available to me I would use a 7 1/4 circular saw with a cut-off blade. It would tear through them like butter. Clamp the bars down with a block of wood as suggested above. ---
**Author:** ![Precambrianmollusc](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/precambrianmollusc/32/63_2.png) [@Precambrianmollusc](https://boards.straightdope.com/u/Precambrianmollusc)\ **Post date:** [May 27, 2015, 4:13am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/18 "2015-05-27T04:13:50Z")
So you need to cut through a 1 3/8" wide x 1/16" thick galvanized steel bar If you’re not fussy about a clean cut then make a score mark and bend it back and forth until it snaps. Pound ends flat with a hammer. it is going to look pretty ugly though. Other than that a hacksaw. ---
**Author:** ![jasg](https://avatars.discourse-cdn.com/v4/letter/j/f0a364/32.png) [@jasg](https://boards.straightdope.com/u/jasg)\ **Post date:** [May 27, 2015, 4:14am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/19 "2015-05-27T04:14:50Z")
> [@Mangosteen](#): > > Sorry, should have been more clear. Two pieces 18 inches long each. I would clamp them together in my bench vise & a c-clamp and use my hacksaw. Then I would dress the edges with a file or emery cloth. ---
**Author:** ![bob\_2](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/bob_2/32/3341_2.png) [@bob\_2](https://boards.straightdope.com/u/bob_2)\ **Post date:** [May 27, 2015, 9:14am UTC](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926/20 "2015-05-27T09:14:12Z")
It may be obvious, but bear in mind that the cut edge will no longer be galvanised and therefore subject to rust. [Next page](https://boards.straightdope.com/t/best-way-to-cut-1-3-8-in-zinc-steel-flat-bar-1-16-in-thick/720926.md?page=2)