Learn me, chop saws and cutting discs to go with them.

It is time to buy a chop saw.   I am sure that a HF saw would be fine for a klutz like me, but I would like to know what else is out there.  And just what are the requirements for a chop saw?

Be square at time of purchase and stay square during use?    I guess a 14" model is pretty standard.

What else did I forget?

Right.   Go!

At the workshop, we've got a mostly permanent loan on an older version of one of these*:

It doesn't have the fence portion, but with some angle iron, some clamps, and a protractor I was able to replicate its function.

The abrasive discs aren't particularly cheap, but they seem to last a good while.  I don't remember where I went to get one, but it was either the local hardware store or Lowes or Home Depot.  Might have been Menards.  I'm not big on the HF abrasive discs

You get fairly straight and consistent cuts and it's relatively fast.  You're not going to get a mill-perfect cut edge or anything, but the tolerances are good enough for most things.  When I was building the air filters for the shop, it was invaluable for getting good mitered cuts on my angle iron for the frames.  I'd set the fence, cut all of one particular piece, then reset the fence and do the next and so on.  Saved a ton of time compared to trying to hack them up with the death wheel, and all the puzzle pieces went together with no gaps for easy welding.

* We have all sorts of friends that when they find out we're in need of some sort of tool like that volunteer to let us borrow theirs.  And then when we try to give it back when we're finished, we're told "Oh, I don't really have room for it..  why don't you just hang on to it until I need it.  And I probably won't ever need it".  We've started referring to it as the "tool library"....

I despise those things. Nasty, dusty, sparks and hot metal flying everywhere. The one I bought, I gave away. 

Buy a band saw instead and a chop frame for it. 

I have the harbor freight version. I hate it. Doesn't cut square, blade cuts into the table, makes a mess. I never use it anymore. If I did it again I would buy one with a carbide tipped blade (like thisEvolution S355CPSL – Heavy Duty 14 Inch Metal Cutting Chop Saw W/ 14 Inch Carbide-Tipped Blade | Dry Cut Saw | Miter Saw 45° | Chop Saw For Cutting Metal – Accurate. Powerful. Reliable - - Amazon.com) or get a frame for my band saw like toyman posted. 

I don't like chop saws at all, due to the fine grit they spray everywhere, and the sparks, and the chance of the wheel exploding. Used one for years during construction of Kimini, and while it worked, wanted something better. I ended up getting a true metal cutting saw; it's basically the same thing but uses a high-tooth-count blade. Makes much cleaner cuts and produces shavings instead of grit/dust.

If I could pick just one cutting tool however, it would be a real bandsaw. They're just so versatile there's no getting around it. Since getting that, I haven't used the chop-style saw at all.

Chop saws do not like flat surfaces. So if you are starting on a flat face of a square tube, it will have a hard time piercing the surface to get the cut started.

The cheapest ones seem to go out of tune as the pivot point develops slop.

I have worn out two and since they are less than the cost of a blade for the metal saw versions, I will keep replacing them as I wear them out.

Have not gone to a proper bandsaw as they take up a lot of room.

Tried the HF version and returned it, upgraded to a DeWalt from HD and still wasn't happy so I returned it. Seemed silly to keep a machine that takes up space when I could do a more accurate job, quicker, with 4 1/2" right angle grinder using cut off wheels.

Now that you mention it, my 14" abrasive saw has not been used in probably 6 years and i certainly have better tools for cutting now. It can go into the give away pile.  

Also im pretty sure there is still a pile of rusty metal shavings bonded to my driveway from the last time the abrasive shop saw way way back. 
 

but, its a cheapo old HF one. It does not cut square, but if i recall right is cuts consistently so its easy enough to "fix". But a porta-band for not much more money will do about all the same cutting better, plus its good for a TON more things. 

Toyman! said:

I despise those things. Nasty, dusty, sparks and hot metal flying everywhere. The one I bought, I gave away. 

Buy a band saw instead and a chop frame for it. 

 

This is what I have and it sets up vertical too. I love it but use it most of the time vert. SWAG Offroad makes just a vertical stand that I wish I went with instead.

If you buy a disc kind see if 3M makes a Cubitron wheel for it. They are the best for you 4" grinder by far.

I had an abrasive saw for years. About 10 years ago I sold it and bought an Evolution. Honestly, I'll never use an abrasive saw again if I can avoid it.

I was given a 14" chop saw. I hate it. It made so much spark and dust that I'll do everything I can to not use it again.

In reply to Toyman! :

I hated my stationary bandsaw, so different strokes....
 

A portable bandsaw is much better. 

SV reX said:

In reply to Toyman! :

I hated my stationary bandsaw, so different strokes....
 

A portable bandsaw is much better. 

Look at what I posted again. It is portable. 

The frame comes in very handy for repetitive and accurate cuts. 

In reply to Toyman! :

I like that stand. 
I have my dads very old Milwaukee port-a-band. Still single speed. It has a pipe cutting stand bout like a chop saw base, with a chain vise. 
I also have his decent quality chop saw, and my HF. They are both horrid! Not that the HF is as good, but that quality on is a big a piece of junk as the HF!!!

All the negatives have been covered; back when we were limited to a 1/8" wide wheel on our 4 1/2" hand grinders, I did use mine, and hated it. Now that we can get thin slitting wheels, I just scribe a good straight line , and follow it!

Ive seen the carbide tipped chop saws, but most are high speed, sparks and debris, but better than abrasives 

Milwaukee makes (and I'm sure others) a cold cut saw. Blade is turning slower, flat out eats through metal, and you can touch the end of the metal afterwards. Pricey , but well worth it!

Ever since I bought my metal cutting circ saw, My portaband doesn't get much use anymore. And it's light years past abrasive cutting discs. The metal cutting saw is just so much quicker and cleaner. 

In reply to Toyman! :

More money, but I think this is what I am going to do!

Thank you all!

Another vote for bandsaw here.  I haven't used my abrasive chop saw since I bought one.

I fabbed up a mount for my bench for the SWAG vertical mount.  I use this thing constantly.  Saw is easily removed for blade changes, or if you want to make a not straight cut in something you can't put on the bench.