I have a competition class and kids are always cutting metal. The Dremel we have just takes too much time and kids are in line a lot. I bought a chop saw and it was fast, but I quickly decided that was too much for our classroom environment (middle school). I need an alternative that is efficient and effective. What do you all use?
We have a band saw that we got last year to do most of our cutting, before that we just used a hacksaw and a vice to hold our metal. The hacksaw is pretty effective and cheap
band saw and belt sander is all you will need. A hacksaw will work but it a bit longer.
@3141SLochNutMonster and @FatGorilla
Can I get a link to what you are using…or something similar to it at least? Lots of options out there.
In what way was the chop saw too much? I find that they are very, very good at their job, and everything else is quite time consuming.
Combining it with a bench sander, hacksaw, and a band saw makes for a fantastic workshop.
@AperatureLabs It is a lot of spark and what not flying around. Nothing is more simple and straightforward for sure. But I just am hoping not so “obtrusive” in my middle school classroom.
angle grinder with metal-cut blade
https://www.homedepot.com/p/Avanti-Pro-4-1-2-in-x-1-16-in-x-7-8-in-Thin-Kerf-Metal-Cut-Off-Disc-PBD045063101F/202830994
https://www.homedepot.com/p/Bosch-6-Amp-Corded-4-1-2-in-Small-Angle-Grinder-1375A/100004897
link text
this is an example of one but any hacksaw should work and a vise to just hold down the metal
I typically just use a hacksaw. A low power Dremel if I need to cut something while on the robot. Long strokes with the hacksaw make it go pretty quickly.
Jigsaw with metal blades.
While I can’t personally recommend this as I’ve never tried it, you could consider a 9" table band-saw fitted with metal cutting blades (Bosch BS5912-18M and/or Vermont American 31152).
My team has 9" SKIL bandsaw sitting in the back, but we haven’t even tested the thing as we have a much larger industrial bandsaw right next to it.
Hacksaws are also cheap and easy to transport, but take a little time to cut with. I’m not sure what blades we have, as all of them are worn, but we generally use fine blades for aluminum.
either get a 70-inch bush-hog chainsaw or get some tinsnips
@Joey The Great Fantastic idea! Better than the goat we have tied up in the storage room to chew the parts to size…he just doesn’t know when to stop sometimes.
We use a variety of ways to cut our metal. In urgent circumstances we use metal snips to cut the metal, but if not we use a hacksaw or band saw. We use the band saw most because it offers a clean cut and is efficient. It also has guards that raises and lowers over the band. Heres a link to the saw, which is very affordable:
https://www.homedepot.com/p/Ryobi-2-5-Amp-9-in-Band-Saw-BS904G/205503634?cm_mmc=Shopping|G|Base|D25T|25-9_PORTABLE+POWER|NA|LIA|71700000044155732|58700004615424082|92700038837660384&gclid=Cj0KCQiA8_PfBRC3ARIsAOzJ2urHOadGgd87ZRgJEBS6Yi1OO5t4J9U6hF9X12s38FdwkjNmTOb-vk4aAkVAEALw_wcB&gclsrc=aw.ds
Hopefully this helps in some way 
I am liking this as an option. https://goo.gl/v3x4YF
I like that it can be vertical for long cuts or horizontal for “hands off” safer cutting options for clumsy middle school students. A buddy recommended a portable bandsaw, but I keep having visions of a kid dropping that mid cut.
I use a hacks saw with a fresh blade. I can easily cut through a high strength shaft in 10 seconds and it’s safer and lower tech than some of the other options. Just invest in a good vice and safety googles in case something goes wrong
A hack saw and a vise bolted to a length of 2"x6" board can be taken to tournaments. Students can then either clamp the board to a table or sit/stand on it to brace the vice. It’s a lot harder to set up power tools or establish a safe work area for them at tournaments.
I use a hacksaw blade…
Just the blade? No hacksaw to go with it? 
nope, just the blade.