I've used my inexpensive grizzly bandsaw to rough-cut stock for the past year (link: http://tinyurl.com/5w7epn) but it's loud as hell. I'm moving to a new apartment building where I'll need something quieter.

I was excited about DeWalt's 14" multicutter (Link: http://tinyurl.com/6dybpz) but unfortunately I just found out that it's incredibly loud too.

Does anyone have any creative suggestions? The machine will be used to rough cut 6061 aluminum and will incur light usage (i.e. only a few pieces per month).

I really don't want to use a hand hack saw. I've thought about a pneumatic hacksaw, but am uncertain whether my 2CFM air compressor would support it.

The really nice thing about the DeWalt Multicutter is that it leaves a relatively-square, nicely finished cut (not imperative since the part will still be milling, but nice).

Perhaps I could DIY my own "multicutter" with a carbide saw blade and my own, quieter AC motor?

Budget is up to $750.

Maybe you should just pick up an X2 mill, use it stock and mill but cut the stock. Take light cuts, but you will get a nice finish and it may not be all that loud.

However, why don't you go outside and cut?


-Jason

This is what I have at my home shop and it is exceptionally quiet.

Delta 28-276 Industrial 14 inch Band Saw with Open Stand, 3000 SFPM, 3/4 HP (http://www.toolking.com/products/4471234.aspx?Search=28-276)

(And it's a lot cheaper than I paid for it :eek: )

Maybe you should just pick up an X2 mill, use it stock and mill but cut the stock. Take light cuts, but you will get a nice finish and it may not be all that loud.

However, why don't you go outside and cut?


-Jason

IMHO a mill is probably the worst way to cut up stock quickly and quietly - you need a bandsaw!

I've used my inexpensive grizzly bandsaw to rough-cut stock for the past year (link: http://tinyurl.com/5w7epn) but it's loud as hell. I'm moving to a new apartment building where I'll need something quieter.

I was excited about DeWalt's 14" multicutter (Link: http://tinyurl.com/6dybpz) but unfortunately I just found out that it's incredibly loud too.

Does anyone have any creative suggestions? The machine will be used to rough cut 6061 aluminum and will incur light usage (i.e. only a few pieces per month).

I really don't want to use a hand hack saw. I've thought about a pneumatic hacksaw, but am uncertain whether my 2CFM air compressor would support it.

The really nice thing about the DeWalt Multicutter is that it leaves a relatively-square, nicely finished cut (not imperative since the part will still be milling, but nice).

Perhaps I could DIY my own "multicutter" with a carbide saw blade and my own, quieter AC motor?

Budget is up to $750.

How quiet does it need to be? I have a Jet 6"x4" bandsaw that claims to be 66dB - I should actually measure it as I have a sound meter, but it's quiet enough cutting aluminium to not have to shout to talk over it. It wasn't cheap, but it is probably the most important tool in my workshop - every part starts with a saw cut!

...this would be affordable to all of us:

http://www.dakecorp.com/cold-saws.html

http://www.maxisaw.com/

unless of course one can be built in a homeshop (wink, wink...nudge, nudge)

Try using a plywood table on top of your metal table of your bandsaw, it might absorb the some of the sound.

Speeds - I can't go outside and cut because I live on the Upper East Side in Manhattan! Not to mention, I do my best to keep my hobby "invisible" to my landlord/neighbors. I'm not breaking any rules, but I can't imagine they would love the fact that I run a CNC Mill in my apartment (albeit only a TAIG).

Pinman & Digits - thanks for the suggestion! Perhaps I've just been tainted on my small, cheap, crappy & noisy grizzy band saw. I'll have to look into a delta (perhaps a smaller unit, as I'm quite limited on space). I'm sure 66db would be fine.

If your only cutting AL, then I would recommend a wood bandsaw. They have a higher sfpm and are better suited to cut AL speed wise. Just make sure you find out what bearings it uses first. Or fabricate some covers for the bearings that are on them and a Wiper.

This bandsaw here is a standup unit but can cut the material much better. See the bandsaw here (http://www.wttool.com/product-exec/product_id/14905/nm/14_4_Speed_Woodcutting_Bandsaw_WT_Import_).

Or, if space is a major concern, you could go with a benchtop Band saw like this (http://www.lowes.com/lowes/lkn?action=productDetail&productId=251652-46578-CB6Y&lpage=none) one. This will work to cut the AL well, but will tend to cut off center if you force it to fast. That is with any saw though.

As much as I liked the 4x6 horizontal saw that I had, it is really to slow for larger materials. And intolerable on AL. I went through a few blades when it gummed up and snapped the blade. It causes lots of heat when your trying to power through the stock with the horizontal and it kills the blade.

I had used my 4x6 horizontal and a little Benchtop 9" ryobi for a long time. Until I started trying to cut larger block stock. Then I decided I needed to move up to something that would handle the job.

I ended up getting 2 new bandsaws, one that would handle both wood and metal, then the horizontal for larger, longer stock.

They are here
http://www.grizzly.com/products/g0621
http://www.grizzly.com/products/6-1-2-x-9-1-2-Metal-Cutting-Bandsaw/G4030



If you are cutting any kind of steel, get a Horizontal and a good blade and you will be much happier. Then get a small benchtop saw for small AL stock. You will be limited to about 4" high though through the throat on most of these. The taller the stock, the slower the feed.



As for the noise, I can only recommend getting out of the apartments and get a house. I'm not trying to be sarcastic, but there are many things that apartments cause you to loose out on. Yes, a house is more expensive. And if your renting, I'm sure it is more so in your area.

The problem is that your wanting to do things in a place that isn't really designed for what you want to do. It's like saying I want to add a swimming pool to the second bedroom in your apartment. We all know that won't work very well and may destroy the place. Likewise, with all of the tooling you have, you will be destroying the peace.

With apartments, you are limited in so many ways. Parking, room, utilities (On Some), etc, etc. I know, I've been there. But I will never go back to that.

I don't know if there is a place there, But I know one guy that rented out a storage building per month that had power and lights in it. He set up shop in it and that is where he worked on projects until his house was re-built. There may be rules against that in your area though, so check first.

cjdavis618 - Many thanks for your thorough post!

Just an FYI re: the apartment - I live in Manhattan (NYC) and if I were to buy the apartment that I rent, it would cost about $900,000. In this current environment (still overprice), that's a poor use of capital, so I simply have to make-do with my rental. My job (which supports my milling hobby!) requires that I live in NYC, hence why I can't get a suburban house. I've looked into storage units/basements to work in, but haven't had any luck so far.

If I lived in a suburban home, I would have a Haas VF-2 instead of my TAIG ;)

That Hitachi looks great! Do you have any experience with it? I just want to make sure it's motor is reasonable quiet (i.e. not much louder than a TV or vocal-levels).

No problem. I just don't like limits. :)

As for the motor on the small benchtop, the Ryobi 9" that I used was very quiet. But when you put the metal to it, it would rattle a bit since it was mostly plastic. That being said, it is small enough that you could build a small enclosure around it and keep the sound level low. And would make for easier clean up.

I can only recommend going to a home store and having them turn one on and listen to it. I haven't used the Hitachi, but their tools get high reviews and actually have a little mass to them as opposed to the Ryobi I had. You can get non-ferrous metal blades for the Ryobi. I got my setup at a home Depot.

If you have a common size stock, I would be glad to show you the difference in speed of cut between the saws that I have now. To give you an idea what the difference is in speed. The saw size has little to do with it, other than the Surface feet per minute of the blade.

I would certainly agree that a house is preferable for this hobby but with the US and UK housing markets in free fall, I've given up on buying one this year.

Given that you are in an appartement, the way I look at it is that I try not to exceed the noise profile of all the things your neighbours expect you to have in your appartment and to only use them at reasonable hours.

So, that gives you ten minutes of very nasty noise (80dB+) about once a week - like vaccuum cleaner would produce, and longer periods of lower level noise/vibration similar to a washing machine. My mill sits on vibration dampers in a flood coolant enclosure which I have lined with soundproofing materials, and is practically inaudible when drilling and about ~65dB outside the enclosure when milling. So, if you have the room, you could always put your saw in a sound-proof plywood box - I'm guessing you don't have 30ft 6x4" bars of 6061 to cut up in your appartment ;)

Digits - Unfortunately, I'm using my TAIG mill in my tiny apartment to mill solid block aluminum 5 liter V8 engines from scratch for formula-series racing cars. Your suggestion to limit my cutting dimensions are totally inadequate.

J/K ;) I probably shouldn't post this thread, for fear that someone will actually think that someone is milling engines on a TAIG. ;)

I think the sound proofing idea is a great idea. Would love to see pictures of your setup! I also agree with your logic re: limited amounts of sound a few times per month.

I'll definitely post pictures of my new room once I complete the move. FYI: here's my current setup: http://tinyurl.com/65ua4j

Mine are only 20 ft. :p


:D

I think he can pull it off with the benchtop without a problem. You can always turn on the vacuum while cutting. lol... :D

CJ - I've done that! I'll run the vacuum or have my fiancee blow-dry her hair. Makes it sound much more innocuous ;)

They are low speed and due to solid construction very accurate and make not too much noise.
http://www.brobo-usa.com/machines.cfm
With a fine blade they are really good. Have a look at one and get a demo.

A band saw is probably your best bet. Most of the noise is not from the turning of the machine but from the blade. I use a multi-speed Wilton 14" band saw to cut all types of metals from aluminum to stainless. The proper speed and feed and the right blade makes all the difference. There are specific blades for non ferrous metals that cut fast and relatively quiet.

Bill

Neil - those are $3000+! I have a generous budget, but not that much!

To all: I should probably clarify: my current cheapo-band saw (see: http://tinyurl.com/5w7epn) is too loud - but it's the motor that is too loud (sounds like a shop-vac, only twice as loud), not the band-saw cutting noise. So I think all that I need to do is find a smaller, high-quality band saw which has a normal/quiet motor.

I think the problem with the one you have is that being portable they have chosen a high rpm motor in order to get the necessary hp from a physically small motor. Hence all the noise is from the motor/fan. I just found one on the net rated at 13,000 rpm!

I have a small, portable metal cutting horizontal band-saw that has a regular AC induction motor rated at 1500 rpm. When running you can hardly hear the motor or fan, just the cutting action, which on a light set cut is not much more than a human operated hacksaw.

I don't have access to my machine at the moment and all those I can currently find on the net are the dreaded high-speed motors.

However I think the key is a small band-saw with an AC induction motor. I think you will get a reasonable quality one in the USA for 300 or 400 USD.

Phil

Neil - those are $3000+! I have a generous budget, but not that much!

To all: I should probably clarify: my current cheapo-band saw (see: http://tinyurl.com/5w7epn) is too loud - but it's the motor that is too loud (sounds like a shop-vac, only twice as loud), not the band-saw cutting noise. So I think all that I need to do is find a smaller, high-quality band saw which has a normal/quiet motor.

I think the problem with the one you have is that being portable they have chosen a high rpm motor in order to get the necessary hp from a physically small motor. Hence all the noise is from the motor/fan. I just found one on the net rated at 13,000 rpm!

I have a small, portable metal cutting horizontal band-saw that has a regular AC induction motor rated at 1500 rpm. When running you can hardly hear the motor or fan, just the cutting action, which on a light set cut is not much more than a human operated hacksaw.

I don't have access to my machine at the moment and all those I can currently find on the net are the dreaded high-speed motors.

However I think the key is a small band-saw with an AC induction motor. I think you will get a reasonable quality one in the USA for 300 or 400 USD.

Phil

I think Phil's hit the nail on the head - my quietish bandsaw uses a 4-pole, 1430 1/2HP motor. I actually think it is quieter than I am with a hacksaw, simply because there's no backstroke.

Digits, Phil, etc - thanks. Your comments re: avoiding the portable-size b/c of noise make sense!

I'm still somewhat limited on size. Would something like this work: http://tinyurl.com/57rqpg (The Delta 9" for $137)? It's below budget, but nothing wrong with that.

The speed is 3000 SFM. Blades are 1/8-3/8 x 59.5". Looks like there's a 14 TPI blade available.

That delta is laid out the exact same way that my Ryobi was. I believe the Delta had heavier plastic for the covering.

Just make sure you have a way to clean up around it. They get really messy with all the little chips.

If you need a demo of the difference in cutting speeds from your 190sfpm to the 3000, let me know. I like excuses to get the tools running. :)

CJ - I'd love a demo!!!

Like I said, this will be exclusively with 6061. Most of my rough cutting will be with pieces about 0.75" (height of part being cut) x 2" (depth of part being cut)

Sure. What size stock do you normally cut?

Here's a good example: http://tinyurl.com/6r5vs9 That piece starts as a rough stock that is 0.625 x 2.25 x 12". I cut the 12" length into 6 pieces, each about 2" wide.

No problem. I have some stock that is the same.

I have to head out shortly, but I will get that as soon as I get back.

Chris.

Looking forward to the results! Please let me know how I can return the favor.

All you gotta do is watch it. :) And laugh at a fat guy cutting metal on a bandsaw.

Maybe it will help others a bit about ways to cut this stuff.

Digits, Phil, etc - thanks. Your comments re: avoiding the portable-size b/c of noise make sense!

I'm still somewhat limited on size. Would something like this work: http://tinyurl.com/57rqpg (The Delta 9" for $137)? It's below budget, but nothing wrong with that.

The speed is 3000 SFM. Blades are 1/8-3/8 x 59.5". Looks like there's a 14 TPI blade available.

My bandsaw is portable - I had a 'no tool I can't lift' policy before I built my big mill! It's about 26kg, because it's about 90% cast aluminium! That's also why it was over £300!

The main functional difference between a horizontal bandsaw and a vertical bandsaw is - what size stock you intend to cut. With a horizontal bandsaw the stock is stationary and the blade/head moves. With a vertical saw (with a table) the stock moves and the blade is stationary. So a horizontal is good for turning long stock (effectively unlimited length) into shorter stock. A vertical is really only good for turning shortish stock into even shorter stock (the length is limited by the throat). However the big advantage of a vertical is you can use it to rough out the final shape of the part, which I can imagine would be a significant advantage if the milling is to be done on a Taig. If you have USD 750 plus noise is an issue then a good solid cast iron metal cutting (read low sfm) vertical with an ac induction motor might be the best.

I'm not sure about the 3000 sfm if noise is an issue. High speed cuts are quick but the faster you cut the greater the energy input which means the greater the potential for noise.

In my limited experience vertical bandsaws tend to be noisier than horizontal, possibly due to the clamping of the stock on the horizontal.

Come to think of it probably the quietest machine tool in a commercial workshop would be a powered hacksaw.

Phil

CJ - I'd love a demo!!!

Like I said, this will be exclusively with 6061. Most of my rough cutting will be with pieces about 0.75" (height of part being cut) x 2" (depth of part being cut)

I have the Delta 14 inch bandsaw, it's very quiet. I have had a hard time cutting aluminum with it though- can't seem to find the right blade.

I had Delta 9-inch and had some serious problems keeping straight-line cuts straight.
I'm currently looking into blade options for my Hitachi 12-inch compound sliding mitre saw. Not a good option for you- WAY TOO LOUD!

Hi,

This is my first post... I have been lurking and reading quite a while. With a little project work and a really quiet motor, this this type of power reciprocal hacksaw setup would probably be quieter than any of the solutions that I have seen mentioned. Especially if the device were placed on a rubber mat to dampen vibrations. And it uses inexpensive replaceable blades to boot! The motor wouldn't even have to be more than 1/4 hp... something like a washing machine motor. I should be pretty easy to build as well.

If you, or anyone else are interested in pursuing this, let me know here and I will post the rest of the pages of this article... :)

http://forum.lugerforum.com/lfupload/ehacksaw.jpg

CJ - any update on the demo cut?

How about a jigsaw blade on a portable sewing machine?

I use my Bosch 10" compound sliding miter saw with a Freud "Thick Non-Ferrous Metals" blade (LU89M010) for cutting 6061 stock.

Blade was $65, the saw a bunch more. Get a cheap one.

Spray with oil, make cut, remove stock. About 10 to 15 seconds of noise. Surprisingly, it is quieter than cutting wood. Makes a CLEAN accurate cut, too. Like butter, as the saying goes.

Like suggested by others, time the cut and cover it with some other sound like a vacuum and you will have no problems.

-AJ

CJ - any update on the demo cut?

Sorry, I should have said in my last post I was leaving town. I just got home this evening from a trip to St. Louis for work. I'll get that up soon, I have to move some things around in my shop so I can get to it. :drowning:

I use this and the optional stand. No legs on the stand, just leave it on a workbench. Variable speed.


Amazon.com: Milwaukee 6232-6 6 Amp Portable Band Saw: Home Improvement

Amazon.com: Milwaukee 48-08-0260 Band Saw Table: Home Improvement

I feel your pain. I live in Boston but fortunately get free run of the basement. I also use a portable bandsaw just like that and it works because the girl who lives above the basement has a dog that barks too much. I don't complain about the dog and she doesn't complain about the bandsaw. I'd get to know my neighbors real well--you want them to call you instead of the building manager. I also take note of when she's not home and go to town.

I'd also spend some time trying to get to know some of the artist/hobbyist groups or that sort of thing who have access to shared workspace. Then you could just go once a week and cut your stock and be done with it. 900k on the UES mustn't be a very big apartment. You're definitely pushing the limits there!