# How do I cut metal? **URL:** \ **Category:** Factual Questions\ **Created:** [July 29, 2001, 6:56am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144 "2001-07-29T06:56:15Z")\ **Posts on this page:** 17\ **Page:** 1
**Author:** ![red\_dragon60](https://avatars.discourse-cdn.com/v4/letter/r/ce73a5/32.png) [@red\_dragon60](https://boards.straightdope.com/u/red_dragon60)\ **Post date:** [July 29, 2001, 6:56am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/1 "2001-07-29T06:56:15Z")
I want to cut a piece of steel or aluminum sheet to make a spear tip for a costume I am designing. I have a propane torch and a grinder. However, I think these won’t cut it (pun intended). How could I do this? I want the metal to be thick enough to hold it’s shape, but still easy enough to cut. Thanks! ---
**Author:** ![stuyguy](https://avatars.discourse-cdn.com/v4/letter/s/ec9cab/32.png) [@stuyguy](https://boards.straightdope.com/u/stuyguy)\ **Post date:** [July 29, 2001, 7:23am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/2 "2001-07-29T07:23:36Z")
For very thin metal, like the thickness of a tin soup can, use tin snips. A jig saw with a metal-cutting blade can also do the trick for thicknesses of say 1/16 to 1/8 inch. For thicker metal, all the way up to the thickness of a prison bar (!), use a hack saw. ---
**Author:** ![mmmiiikkkeee](https://avatars.discourse-cdn.com/v4/letter/m/edb3f5/32.png) [@mmmiiikkkeee](https://boards.straightdope.com/u/mmmiiikkkeee)\ **Post date:** [July 29, 2001, 7:39am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/3 "2001-07-29T07:39:06Z")
Yes, hacksaws are very good (make sure to put the blade in the correct way around - I can’t tell you how many times I’ve seen people use them backwards and complain they don’t cut)… or an air-powered cutting disk or die-grinder (which I guess you don’t have). Any metal thick enough to require a hacksaw will be thick enough to be a real spear tip; yikes! Is it for decoration on a kid’s costume or for real on a real-life replica of mid-evil armor? Don’t loose an eye! ---
**Author:** ![sewalk](https://avatars.discourse-cdn.com/v4/letter/s/b3f665/32.png) [@sewalk](https://boards.straightdope.com/u/sewalk)\ **Post date:** [July 29, 2001, 8:17am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/4 "2001-07-29T08:17:51Z")
I would strongly suggest a plastic or wooden tip with a metallic color painted on it. If you’re just designing a costume, lethal authenticity is probably not a good idea. Even an aluminum tip would be dangerous. On top of that shaping plastic or wood would be much easier and less expensive. ---
**Author:** ![DocCathode](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/doccathode/32/18773_2.png) [@DocCathode](https://boards.straightdope.com/u/DocCathode)\ **Post date:** [July 29, 2001, 3:58pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/5 "2001-07-29T15:58:22Z")
I’ve also been working on a costume. I have all the metal plates I need for armor, and a method to join them. I want to know how I can make the plates’ edges safe without sanding off or otherwise removing a lot of metal from the edges. BTW I am making a weapon for the costume, it has no sharp edgesand is mostl plastic. ---
**Author:** ![DocCathode](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/doccathode/32/18773_2.png) [@DocCathode](https://boards.straightdope.com/u/DocCathode)\ **Post date:** [July 29, 2001, 4:01pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/6 "2001-07-29T16:01:17Z")
I can type! I swear! I’m over at my folks place, and my father’s @#@$ MS keyboard is shot. Crappy keyboards, and spacebars that stick. Yet another reason to hate Bill gates. –Oh and is there any special information I need when cutting brass? ---
**Author:** ![Squink](https://avatars.discourse-cdn.com/v4/letter/s/b5e925/32.png) [@Squink](https://boards.straightdope.com/u/Squink)\ **Post date:** [July 29, 2001, 4:09pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/7 "2001-07-29T16:09:15Z")
> [@](#): > > how I can make the plates’ edges safe without sanding off or otherwise removing a lot of metal from the edges. You can make them safer by slathering them with a good thick coat of epoxy. The 5 minute setting variety should be good enough for most purposes.Silicone caulking and rubber cement are probably not durable enough for your needs. ---
**Author:** ![stuyguy](https://avatars.discourse-cdn.com/v4/letter/s/ec9cab/32.png) [@stuyguy](https://boards.straightdope.com/u/stuyguy)\ **Post date:** [July 29, 2001, 6:07pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/8 "2001-07-29T18:07:44Z")
Despite your reservations, I’d say your best bet is “sanding” after all. Except you want to use a file, emory cloth/paper (sandpaper is for wood, emory cloth/paper is for metal) or steel wool. Any of the above will take the sharp edges and burrs off without really removing any noticable amount of metal. Be careful though, they will scratch the shiny front surfaces if you don’t rub carefully. ---
**Author:** ![Chronos](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/chronos/32/134_2.png) [@Chronos](https://boards.straightdope.com/u/Chronos)\ **Post date:** [July 29, 2001, 7:02pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/9 "2001-07-29T19:02:33Z")
If you use an emory board, make sure that it’s real emory. Most “emory boards” just use ordinary sand, which is fine for fingernails (their most common use), but brass is harder than fingernails. Real emory is low-grade corundum (as in rubies and sapphires), which makes it the second-hardest natural substance known. ---
**Author:** ![casdave](https://avatars.discourse-cdn.com/v4/letter/c/c6cbf5/32.png) [@casdave](https://boards.straightdope.com/u/casdave)\ **Post date:** [July 29, 2001, 7:04pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/10 "2001-07-29T19:04:28Z")
For such costumery plasticene(plastic clay?) formed into the desired shape and painted is a wonderful thing, far less work is needed to produce visually acceptable results. ---
**Author:** ![red\_dragon60](https://avatars.discourse-cdn.com/v4/letter/r/ce73a5/32.png) [@red\_dragon60](https://boards.straightdope.com/u/red_dragon60)\ **Post date:** [July 30, 2001, 1:32am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/11 "2001-07-30T01:32:28Z")
Well, I am using it for a sci-fi costume for conventions and such. I will probably not grind an edge into it, as that might get me in trouble. I want it to be useable also, uowever strange it sounds. I plan on padding the tip and sparring or at least practicing with it. ---
**Author:** ![kniz](https://avatars.discourse-cdn.com/v4/letter/k/c37758/32.png) [@kniz](https://boards.straightdope.com/u/kniz)\ **Post date:** [July 30, 2001, 4:40am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/12 "2001-07-30T04:40:32Z")
Sounds like you were wanting to use an **Acetylene torch**. That will cut metal, but should only be used by an expert and really isn’t the right tool for your project. Use a saw with metal blade, as has already been mentioned. ---
**Author:** ![tisiphone](https://avatars.discourse-cdn.com/v4/letter/t/bbe5ce/32.png) [@tisiphone](https://boards.straightdope.com/u/tisiphone)\ **Post date:** [July 30, 2001, 7:00am UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/13 "2001-07-30T07:00:19Z")
I use a [scroll saw](http://www.skiltools.com/cd-html/s3k00043.htm) with a metal blade to cut out some pieces, and a dremel with a cutting wheel for others. To get rid of the razor edge, I use really fine [files](http://www.widgetsupply.com/html/gt-files.html) and a light touch. Since I’m making pendants and stuff, not removing a lot of metal is a priority. And you might want to use PVC clay for the spearhead anyways. PVC clay is also called Fimo and Sculpey. It comes in various colors, including some pretty good metallics. It works like plasticene, and you bake it for about ten or fifteen minutes on low heat, and it hardens beautifully. A quick coat of clear nail polish and you’re done. ---
**Author:** ![cornflakes](https://avatars.discourse-cdn.com/v4/letter/c/9d8465/32.png) [@cornflakes](https://boards.straightdope.com/u/cornflakes)\ **Post date:** [July 30, 2001, 3:22pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/14 "2001-07-30T15:22:29Z")
I’d just cut it with a hacksaw, then file it smooth and to shape with a mill bastard file. Aluminum will load up (clog) the files though, so get a [file card](https://www.wttool.com:443/wtool/product.asp?pf%5Fid=54960040p&dept%5Fid=221) to clean them as you go. You could probably use your grinder as well, but clogging will be a problem here as well and you will need to redress the wheel. For safety, why not just cut it blunt, file it smooth, and mount the tip in a way that it will easily break away from the spear’s shaft? Maybe you could mount the tip to the shaft with rubber bands. ---
**Author:** ![Kamandi](https://avatars.discourse-cdn.com/v4/letter/k/5daacb/32.png) [@Kamandi](https://boards.straightdope.com/u/Kamandi)\ **Post date:** [July 30, 2001, 11:12pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/15 "2001-07-30T23:12:59Z")
Doesn’t your phaser have a setting for metal cutting? I’d imagine it’s somewhere between “kill” and “vaporize”. 😃 ---
**Author:** ![handy](https://avatars.discourse-cdn.com/v4/letter/h/b5a626/32.png) [@handy](https://boards.straightdope.com/u/handy)\ **Post date:** [July 31, 2001, 2:42pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/16 "2001-07-31T14:42:39Z")
If you have the guts you can use a circular saw with a metal cutter blade. Otherwise try a hardware store & ask them what to use. ---
**Author:** ![Mangetout](https://sea3.discourse-cdn.com/straightdope/user_avatar/boards.straightdope.com/mangetout/32/19_2.png) [@Mangetout](https://boards.straightdope.com/u/Mangetout)\ **Post date:** [July 31, 2001, 3:02pm UTC](https://boards.straightdope.com/t/how-do-i-cut-metal/74144/17 "2001-07-31T15:02:59Z")
For cutting sheet metal, you can get a power tool called a ‘nibbler’ which looks like a jigsaw(scroll saw) but works by nipping tiny chunks of metal away, rather than a sawing action. Probably not worth buying one for a one-off project, but you could probably hire one.