Auto Body Sheet Metal Fabrication: Is Scroll Saw Cutting Practical?

MrCreosote · Jan 6, 2023

I no longer have my bandsaw for precision cutting patches and wondering if a scroll saw might be better than a table mounted saber saw or small wood cutting bandsaw w/metal blade (32 tpi 1/4").

The scroll saw in question is a 1945 Sears/Dunlap (103.0407)

Photo Index - Sears | Dunlap - 103.0407 | VintageMachinery.org

Bondo · Jan 6, 2023

Depends on your skill level. A Sawzall could work in the hands of a skilled person.

Scroll saws have several different blades, like any saw, but it is an option.

DDoug · Jan 6, 2023

Your a wanker if you don't use a Plasma cutter.....just like on T.V.

snowman · Jan 6, 2023

I have used them for aluminum. The blade would try to grab, and lift the sheet metal. So lubrication as well as slow feed and a fine pitch blade will be key if it works.

MrCreosote · Jan 6, 2023

Thanks for the replies. Some comments:

SAWZALL: I use templates to make precise fitting pieces. Cutting sheet stock with a Sawzall won't do it. But a saber saw will. However when making small pieces like 1" x 1" and smaller, you need a table like a bandsaw.

PLASMA CUTTER: This is not a process for precise cutting - you cannot nibble with a plasma cutter. I purchased an ESAB 875 50a 1.25" sever thinking I could do precise work but the precision isn't there.

SCROLL SAW w/ALUM: Alum get gummy when cut. Steel might be a different story. The limiting factor may be the available types for the different types of scroll saw blades. A good heavy blade (by scroll saw standards) would probably work the best.

Need to find someone who has gone this route.

true temper · Jan 6, 2023

I have a friend that has one of these, https://www.supplyhouse.com/Milwaukee-2476-20-M12-FUEL-16-Gauge-Variable-Speed-Nibbler he says its bad ass good.

IceCzar · Jan 6, 2023

it all works
as long as you can actually manage to clamp it sufficiently
(the real skill in fabrication)

Spud · Jan 7, 2023

In the tech college autobody program I was in we used shears and nibblers for cutting small patches.

gbent · Jan 8, 2023

MrCreosote said:
PLASMA CUTTER: This is not a process for precise cutting - you cannot nibble with a plasma cutter. I purchased an ESAB 875 50a 1.25" sever thinking I could do precise work but the precision isn't there.

If you want precision with a plasma you need a Hypertherm. On their bigger power units Hypertherm has the ability to use the consumables from the smaller torches for better cut quality. You are doing the equivalent of hunting squirrels with a .300 Win Mag and complaining it ruins to much meat.

DDoug · Jan 9, 2023

Spud said:
In the tech college autobody program I was in we used shears and nibblers for cutting small patches.

Yes, and in Kindergarten they gave us scissors that were rounded on the ends, no "pointy bits".......

Strostkovy · Jan 9, 2023

What thickness material? 20 gauge or so and I would think a few styles of hand shears would be all you want or need.

16 gauge would probably warrant something better.

Spud · Jan 9, 2023

DDoug said:
Yes, and in Kindergarten they gave us scissors that were rounded on the ends, no "pointy bits".......

That's nice dear, and I'm sure the thread starter will put this info to good use.

MrCreosote · Jan 9, 2023

Strostkovy said:
What thickness material? 20 gauge or so and I would think a few styles of hand shears would be all you want or need.

16 gauge would probably warrant something better.

18 ga (.048) is typical. But .062, .093, and .125 sometimes which need a saw.
I have all the WISS aviation snips - even the "blunt nose" for 16ga.

Snips don't work too good cutting when you can't "roll up" the discarded piece - have seen the method of using the LH and RH to cut a large sheet in half (that's where the big bandsaw comes in which spoiled me.)

I could use my air nibbler to rough cut, then snips to trim for thin.

DDoug · Jan 10, 2023

Spud said:
That's nice dear, and I'm sure the thread starter will put this info to good use.

No, maybe you can simply sit on your hands for awhile ....
Every body shop I have been in, or seen on T.V./Youtube has a plasma cutter.
Adults use proper power tools.

BT Fabrication · Jan 10, 2023

MrCreosote said:
18 ga (.048) is typical. But .062, .093, and .125 sometimes which need a saw.
I have all the WISS aviation snips - even the "blunt nose" for 16ga.

Snips don't work too good cutting when you can't "roll up" the discarded piece - have seen the method of using the LH and RH to cut a large sheet in half (that's where the big bandsaw comes in which spoiled me.)

I could use my air nibbler to rough cut, then snips to trim for thin.

for sheet metal, air nibblers work the best to cut odd shaped parts, unless you have a foot brake shear.

Spud · Jan 10, 2023

DDoug said:
No, maybe you can simply sit on your hands for awhile ....
Every body shop I have been in, or seen on T.V./Youtube has a plasma cutter.
Adults use proper power tools.

And what makes you think we didn't have a plasma cutter at the tech school and did not use it when it was the best tool for the job. Shears can be manual or powered.

If you watched videos of pros shaping / replacing sheetmetal you would know they use shears and nibblers, in addition to plasma cutters, pullmax and large stationary shears. Pros also use beverly shears, which are manual.

Here is J.J. using a Trumpf shear.

and here is Fay Butler using handheld power shears.

bsg · Jan 10, 2023

I would use a Beverly shear..........or Kett shears to cut material from a large sheet.

You could also use a Heck trace a punch........

MODEL 4 Trace a Punch | Heck Industries

MODEL 4 Trace a Punch | The world leader in plate beveling machines. Heck offers a complete line of quality and patented hand held bevellers, bench models, and power feed machines

heckind.net

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Auto Body Sheet Metal Fabrication: Is Scroll Saw Cutting Practical?

MrCreosote

Plastic

Bondo

Hot Rolled

DDoug

Diamond

snowman

Diamond

MrCreosote

Plastic

true temper

Stainless

IceCzar

Aluminum

Spud

Diamond

gbent

Diamond

DDoug

Diamond

Strostkovy

Stainless

Spud

Diamond

MrCreosote

Plastic

DDoug

Diamond

BT Fabrication

Stainless

Spud

Diamond

bsg

Titanium

MODEL 4 Trace a Punch | Heck Industries

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