cutting sheet metal...

[bugandcab]

what is the best tool to cut sheet metal. I have to replace one of my panels that is rusted out towards the bottom and I want a clean cut.
Thanks

[Radar74SB]

try and avoid using tin snips or a cutting torch as they will warp the good metal that you are not removing.i like using an angle grinder with a cutting disk. a dremmel works good for the tighter areas

[john walker's workshop]

an air saw works great. looks like a mini sawzall. no warpage or sparks, and a very thin cut.

[CJM722]

I've had the best luck with Tin Snips for thicker metal i used a Dremmel

[BUGMAN II]

sawzall

[keifernet]

I have em all, die grinder cut off wheel,
( does anyone like the taste of carbide in the morning! YUK!) 4 or5 pairs of snips, torches, different grinders ect.. even a plasma arc cutter! but after years and years you figure out just which one to pick up for what spot. And 90 percent of the time the SAWZALL is the tool of choice!

[[email protected]]

Please pardon my ignorance but what's a "sawzall"?
I'm thinking its a reciprocating hack saw with an open ended short blade. Either electric or driven by compressed air. That being so how does one get it started if there isn't an edge to attack? eg a rusty patch. D'oh! I guess you drill a hole in the middle of what you don't want!!
I'm thinking of buying a Dremel for the flexibility it gives in tight spaces & the wide variety of grinding wheels so I can see the need for both.

[Rubyred, 2056]

I used a simple jig saw with metal blades. You can pick a jig saw up for about 30 bucks at Wal-Mart and the blades are pretty cheap. Best of all, is the jig saw will come in handy around the house. When you are cutting the metal have patience and take your time. Be sure to have a helper support the metal as you cut or you will bind the blade.

[keifernet]

You can get an idea of what is out there Sawzall /blade choice wise by going to sears or a home improvement store.
I use a HD name brand about 180.00 but I abuse it nearly every day.... Sears has a small model that would suffice for a home/shop that is only about 60.00 or there are others (less amps rating on the motor is the deal) for around 100.00...
Dremels are basically to light weight for anything but very small detailed work (IMO) and I would burn one up in a week! You can't put a nice 9-12 or even 14" metal blade in a jigsaw but you can in a sawzall.
And the cutting technique comes with experince, expect to "bend a few blade" the nice thing is you can straighten them out after they cool down with pliers or the bench vise and keep going... I buy 10 packs "Blue- Mol" at home depot for about 10 bucks, they are the best value for the $$$$ the longer "demo blade" is about 2-3 bucks each, but I have completely cut up numerous super beetles with just one blade...

[Mowser]

the combination of a die grinder/ angle grinder/ and reciprocation saw should cover all the different areas. None of which are very costly. I use a die grinder to start the cut and then go hard with the sawsall/ reciprocating saw. Works well and the blade width is about the same.