notching 1/4" steel

[lati_cz]

I need to notch 1/4" thick steel (flat bracket). Each notch is approx 3'' deep and 1/2" wide. It's on fixed metal structure, so I can't take it to a shop. I have 60 to make....
I have small and large grinder. What my best and fastest way? Thanks

[cx]

I'd need to know a good bit more about the project, Michal, in particular how clean these cuts need to be. Do you have access to a plasma cutter?

[dhagin]

Porta bandsaw, sawzall, grinders, etc. maybe drill a hole at end and bandsaw to the hole. Can clean up with grinder.

Or what cx said.

Of course, you know to consider the structural ramifications of this notch. Right?

[Davy]

Those 1/16 thick cut off blades are sure handy. I seem to use a lot of them any time I'm doing any kind of metal work.

[lati_cz]

I have 6 steel posts I beams 8 x 8" x 10' installed vertically on concrete porch. Each has 5 L bracket approx. 3 x 3 x 1/4" welded on each inner wall (both sides). I need to make notch (RED mark) on center of each bracket approx. 1/2" wide. The posts are powder coated. The cut doesn't have to be perfect, it will not be exposed, will be covered with wood. Bracket have not structural purpose, it's spacer for wood filler.
I do not have plasma cutter, I can get/rent one I guess....

[cx]

I'm still a little confused, Michal. Are you cutting the vertical surface of your angle bracket, or the horizontal? Might help to know the purpose of the cut.

The cut-off blades Davy mentions are moderately wonderful, but you can't cut to a 3" depth with even the 5" discs and you can't cut the dead end even if you can get enough depth. Doesn't look like you could pre-drill that dead end before the cuts, either. That's why I mentioned the plasma cutter.

[Davy]

Yeah, those cut off blades won't cut 3 inches deep. I've even put a 6 1/2 inch metal cutting blade on a grinder and it will barely cut over 2 inches deep when it's full size. The plasma cutter sounds like the way to go but you have to deal with the sparks, etc.

[John Bridge]

They have gas engine circular saws that you can rent. They can throw you, though, if you're not careful.

[lati_cz]

here it is, I am trying to think about other options avoiding to cutting the notch.... it's sideways I tried to rotate, came up the same. Piece of paper indicates the notch.

[cx]

Originally Posted by CX, Post 6

Might help to know the purpose of the cut.

[lati_cz]

The posts are part of trellis. The "hollow" sides of I beams will receive 2 led rope lights, one on each side installed vertically. Each post will have 4 lights. There will be wood filler hiding the lights with approx 1/4" space on each side between metal and wood where light will go through. The light has decorative purpose only.
We tested first light yesterday, customers would prefer light to be more even/diffused. The single led elements reflects inside beams and are very obvious. The light looks "dotted".
I hope by reducing the amount of rope light to one and moving towards center should eliminate the "dotted" look.
I am thinking about just making notch on front of bracket and attaching the rope light to wood filler.....

[lati_cz]

this is the mock up piece, unfortunately the pic is blurry and "dotting" is not so obvious. The unevenness and shading was caused by failure of hot glue gun, I fixed the issue.

[cx]

I understood the overall concept of the project, Michal, but I still don't know the purpose of the notches.

[lati_cz]

Brackets are in way of moving lights to center of beam.

[wwhitney]

Maybe find different rope lights with built-in diffuser?

Or add a diffuser in the gap between the wood and the steel?

Both seem easier than notching the steel.

Cheers, Wayne