Cutting 1/8" steel plate

[brad hays]

I need to cut this squarish hole out of this 1/8" steel plate and the best tool I've got to do it with is a 4 1/2" cut wheel. The white square in the picture is 1 sq in so you can see how my big cut wheel isn't quite nimble enough for the job. If I drilled the corners is there any kind of jig saw blade that would do it? Or maybe some kind of oscillating tool blade? I've got an oscillator but I haven't used it to cut metal yet.

504574

[John Ziebron]

If you lived near me I could make a template and cut it out with my plasma torch in less than a minute. They do make fine tooth jig saw blades for cutting metal if you have one. I've had good luck with the Bosch brand. They are meant to cut thinner gauge metal but should work for 1/8 inch, just take longer. You would have to drill holes at all the inside corners first.

[Bill Dufour]

I would score the cut lines with an angle grinder as deep as possible. Then use a jig saw or jigsaw blade in a reciprocating saw. Use cutting oil to cool the blade or even just water will help.
Drill 1/2" holes or so in two opposite corners to start.
Will a hack saw frame be deep enough to cut it?
A metal cutting bandsaw was designed for this kind of cut with a onboard blade cutter and welder.
BilL D

[andy bessette]

Drill press and saber saw.

[Rich Engelhardt]

Diablo makes a carbide blade for cutting through 1/8" to 1/4" steel.
It works quite well.

[George Yetka]

There are jigsaw blades for steel. I have used them up to 1/8"

[Jerome Stanek]

I just cut a 1 inch nut off a trailer hitch using a Harbor freight 1 1/2 inch cut off wheel.

https://www.harborfreight.com/1-1-2-half-inch-cut-off-wheels-3-pack-34749.html

[Rod Sheridan]

Use a jigsaw, super simple…..Regards, Rod

[Bruce Wrenn]

Because you have already drilled holes in corners, use a 3/4" hole saw and remove most of the remaining material. Then file out the corners. Probably take longer to set up, than to do. The reason I recommend using a 3/4", is hole saws tend to wobble, and cut oversize holes.

[Alex Zeller]

Since you drilled the corners I would use the 4 1/2" grinder to cut as much as you can. It'll take longer but I would use a thicker wheel than the usual .045 cut off wheels. Do it on both sides. Then finish up the corners with a jigsaw or sawzall. If you use a .045 wheel it'll most likely be too narrow to get the jigsaw blade into the cut.

[Cameron Wood]

Jig saw.....

[Rich Engelhardt]

Oops - I forgot the op was cutting steel and not aluminum.

[John Ziebron]

Aluminum is soft and a lot of use even use our miter saws to cut it. A jig saw is probably still the best way to do inside cuts in aluminum.

[andy bessette]

John--good post.