How do I Cut cast iron?

Terrebandit

I've got an extra CI grate from my old gasser grill. This one is brand new. I would like to cut this into a 13 inch diameter circle and use it with a CGS spider for searing meat. What's the best way to cut cast iron? I will have to cut numerous small 1/4 to 1/2 inch bars to make this circle pattern out of the pictured grate below. Thanks.

jhl192

A Sawzall or a die grinder.

NPHuskerFL

Angle grinder or a dremel with a metal cutting wheel make a nice clean cut.

Little Steven

Angle grinder w/metal disc. I might go to a welding shop and get it plasma cut.

Ladeback69

All the above. Safety first, don't forget gloves and eye protection.

Maccool

Agree, all of the above...but I'd be inclined to take it to a welding shop. Likely only cost a few $$ and a couple of minutes to get it plasma-cut.

RRP

Back before I had an angle grinder I used my SawsAll to cut this one out.

RRP

RRP said:

Back before I had an angle grinder I used my SawsAll to cut this one out.

Here's another way of looking at it! LOL

Botch

Ron, that looks like a nice clean cut.  I used a Sawzall a lot when I worked construction, but the blades I used must've been more "construction grade" rather than fine-tooth metal-cutting...

RRP

Botch said:

Ron, that looks like a nice clean cut.  I used a Sawzall a lot when I worked construction, but the blades I used must've been more "construction grade" rather than fine-tooth metal-cutting...

Yes they were fine toothed bi-metal blades. I actually cut out 3 of those, kept one and sold the others. That was before BGE made CI for the small eggs. Even in spite of the reciprocating SawsAll movement I only broke one piece of a grate and after looking at it close it had a casting flaw where it broke. 

Terrebandit

Thanks Ron, that's what I need to do.

tridogdude

Use a 4-1/2" grinder with a 1/16" Metabo grinding disc. It will cut it like butter and little to no chatter/vibration.
I would avoid using a sawzall. Bigger chance of breaking your piece. If you do go with a sawzall, use the Milwaukee Double Duty fine tooth blades. They hold up better than their standard one. Clamp the piece down good though.

Terrebandit

tridogdude said:

Use a 4-1/2" grinder with a 1/16" Metabo grinding disc. It will cut it like butter and little to no chatter/vibration.
I would avoid using a sawzall. Bigger chance of breaking your piece. If you do go with a sawzall, use the Milwaukee Double Duty fine tooth blades. They hold up better than their standard one. Clamp the piece down good though.

Thanks man. Are you talking about a bench grinder or a handheld one? Assume handheld angle grinder. @tridogdude‌

NPHuskerFL

That's impressive with a reciprocating saw @RRP‌

grege345

@Terrebandit‌ fwiw this is what I used. Harbor freight special

nolaegghead

Best way is with a band saw and a raked blade.   Cut-off abrasive on a grinder takes longer but works.  Sawzall works fine, bimetallic blade.  Hack saw and some elbow grease works well too.  Pretty much anything that cuts steel will cut cast iron, except cast iron is easier to cut.  Watch excess heat esp uneven, and cast iron will break on a score.

tridogdude

Yeah, a 4-1/2" angle grinder. The Metabo blades are real thin and will cut through it like butter. I use these things at work all the time for steel, cast iron or stainless steel cuts on pipes that are hard to get at with other tools.

A hand held or upright mounted band saw would work good too but most people don't have these tools.
Depending on the hardness and make up of the cast iron you are cutting, doing it with a hack saw or even some metal cutting sawzall blades, you will dull the blades very quickly. The Chinese have been using a fair amount of glass in their manufacturing of cast iron products and this makes it difficult to cut without going through a lot of blades.

Terrebandit

Thanks man.