I'm was just contracted to build console units for this company. The top part of the console where all of the control pieces are mounted (switches, buttons, display units, etc.) is made of 18-20 gauge sheet metal (i don't have the exact specs on me right now). Each top piece is roughly 2' x 1'. The detailed work comes in rounding the outside corners and mounting the display units, which some have very interesting curves to them. All of the cuts into the sheet metal must be very clean, straight, and smooth. For these small curves and rounding of the corners, I think I want to use an Air Nibbler, since these seem to produce the most precise cuts at an affordable cost. Any other suggestions on this? As for cutting the 2x1 sheets out of the 4x8 sheets, what should I use? Can I get away with using a quality jigsaw or should I go with air shears? Will the jigsaw even cut the sheet metal without distorting the edges? I don't mind spending up to $300 each on a nibbler, jigsaw or shears if it's needed. I'm just wondering if I need to?

Let me know your opinion on these nibblers. I'm gonna be using these tools quite a bit, so I don't mind spending the money on the more expensive ones. I'm just wondering if I need to for what I'm doing. LMK what you all think about the need for air sears vs using a jigsaw for the straight cuts. ALL opinions are welcome

Matco Air Nibbler -- $163.50
Cuts up to 18 Gauge rolled steel without distortion.
Cuts tight 1/4" radius with accuracy.
Compact design for tight areas.
Strokes per minute: 210
Length: 7-1/16" Weight: 2.2 lbs.
Part#: RL835 Price: $163.50


Craftsman Air Nibbler -- $189.99
Sears item #00919015000 Mfr. model #19015
Cuts through 16 gauge steel without deforming or burring metal and features a 4.5 mm adjustable die guide and punch for multiple cutting directions. Includes spare punch.
Item Weight 2.25 lbs.
General Warranty 2 years
Cut Width 7/32 in.
Tool Air Inlet Size 1/4 in.
Connector Accessory: Size 1/4 in. NMPT
Motor-Engine: Speed Range SPM 2600 spm
Dimensions: Length 7 in.


Mac Tools Air Nibbler -- $275.99
Will cut steel up to 3/64" thickness and aluminum up to 5/64" thickness
Lightweight, compact design provides smooth operation


SnapOn Air Nibbler -- $290.65
Stock # AT180A
Name Nibbler, Air
Price** $290.65
Brand Blue-Point
Air Inlet Thread Size 1/4"-18 NPT
Width/Depth of Cut 11/32" (4.37 mm)
Air Consumption, free speed, cfm (scfm) [l/min] 3.6 (26) [101.9]
Free Speed 2,000 strokes/min.
Ion Plated Punch (opt.) AT180-30
Overall Length, inches (mm) 7 (178)
Recommended Air Pressure, psig (kPa) 90 (620)
Recommended Hose Size, inches (mm) 5/16 (8) ID Min.
Sound Level, free speed, dBa 90
Description Nibbler
Standard Punch (incl.) AT180-8
Cutting Capacity 16 gauge mild steel (1/16")

 

i think the air shears or even electric powered shears are your best bet. them nibblers are anoying when they get stuck., and they leave a bunch of half moons, if you arent careful about cutting **** out with them.

 

make a drawing and have them laser cut, laser cutting can be done for the cost of the nibbler and with .001" of each other
if you need a quote on laser cutting them send me a drawing and ill give to my laser cutter

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Howitt &raquo;</TD></TR><TR><TD CLASS="quote">make a drawing and have them laser cut, laser cutting can be done for the cost of the nibbler and with .001" of each other
if you need a quote on laser cutting them send me a drawing and ill give to my laser cutter</TD></TR></TABLE>

since you are giving away free laser cutters, send me one

 

Going to a machine shop with a laser/hydro cutter might be better if you are doing a lot of cutting.

 

actually a laser cutter just went on ebay for 8k like a month ago and it would cut 5/16" if I wasnt broke at the time I would of bid on it. A local company bought a new machine that is 6000 watts cost 850K new should been running any day now I cant wait to see it tear thru some 1.5" plate at 50IPM

 

As stated, laser/water jet cutting is your absolute best bet. And if you are doing alot of identical pieces, probably more cost effective than anything else. However, if you are doing "custom" pieces all the time, where they are not all identical, I would say the air shears. The jigsaw will work fine but may leave a somewhat rough edge, which you could clean up with a file, but thats time consuming...time equals money.
As for cutting a piece out of a 4x8 sheet...preferably, just have it cut with a shear at your local metal shop. Not sure of rates where you are, but here I can get it done for a buck per cut or so. If this not an option, get a stright edge(preferrably thick metal, so it cannot warp like wood does), and get two of the smaller sized "quick-grip" clamps. You will have to measure from the edge of your cutter(whatever your using, jigsaw, nibbler, etc.), to the outside of the "base of the tool(base meaning whatever would ride against the straight edge). After you have this measurement, clamp your straight edge according to whatever esize piece you want to cut, plus the measurement you just took on your tool, and whala...a perfect edge to run your tool against. If you measure 3 times, cut once, and keep it tight against your straight edge, you will end up with a perfect cut. Ive used this for years to cut plywood, steel plate, and anything else that comes in big sheets!
GOOD LUCK!
Kyle

 

Thanks for all the replies, a lot of good info here

For the unit, the outside shape is gonna be identical on all of them, so once I get a templet fabbed up, I'm gonna take it to all of the machine shops in my area and see what kinda costs we're talking about for the laser/ water jet cutting. For the middle of the piece, there's gonna be a lot of variety in what's going in there, so I'm definitely gonna have to do those myself. I'm pretty set on getting a nibbler for that, as that's where a lot of detail is gonna have to be put in and I just don't think shears are going to be able to get the tight contours just right (am I wrong here in my thinking?).

About jigsaws, I was at home depot today, and I noticed there was a 36 tooth per inch blade for cutting "extra smooth edges". how would this do? Still going to give me a semi-rough edge?

 

any opinions on which nibbler to get and if the 36 tooth per inch blade for a jigsaw is going to cut smooth?

 

if your questioning the smoothness of a 36 tpi blade your going to be really upset at the terrible finish you get from a nibbler. Don't the gauges have bezels that cover the edge of the cut? I think your best bet would be to make some patterns for the different gauges and use a plasma cutter. A pak25 thermal dynamics unit has the perfect tip for following templates and is more than enough machine for your application. Just leave a little material for finishing. you can use a detail belt sander like dynabrade for finishing. The best is a laser or water jet one other option is to use a whitney hole punch and get different size punches for the corner radius and a rectangular punch (1/8x3/4) to cut the straight sections

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by KFMRC &raquo;</TD></TR><TR><TD CLASS="quote">if your questioning the smoothness of a 36 tpi blade your going to be really upset at the terrible finish you get from a nibbler. Don't the gauges have bezels that cover the edge of the cut? </TD></TR></TABLE>

Damn, is it that bad? The display units do have bezels that can cover some sloppyness, but they need to sit completely flat. I was hoping for a tool that would be able to cut a smooth piece so I didn't have to waste time sanding the edges even. I'll definitely take your other advise into consideration. Thanks! Other opinions still welcome