How to cut a slot in a steel plate?

[ScumOfTheRoad]

I ordered a custom door finger plate from   https://kickplatedirect.co.uk/  http://stevegrahamsales.co.uk/
Might as well give them a plug - they will cut a custom size of kickplate or fingerplate in whatever material you need.

I got a 2mm steel fingerplate which I intend to use to reinforce the lock area on some patio doors - the lock of the patio doors is secured by two bolts which have worked through the metal. Bad design really.

I want to cut a slot in the steel plate 5mm wide by 50mm long. I have drilled four holes and am trying to link them by using a Dremel with cutting disks. I have used up about a dozen cutting disks and have knackered my Black and Decker Dremel-alike tool. And Black and Decker int heir wisdom fastened the case together with Torx screws. But security Torx - so you cant even take apart your own property to fix it. Bad show.

Anyway advice - I have an electric drill. No drill stand. Are there good tools or drill bits for cutting slots in metal?

[ElyDave]

Can you not get a file in there, or failing that slip a junior hacksaw blade through the slot, then put the handle on and go from there?

[Wobbly John]

I'd use hand tools - hacksaw (Abrafile blade to get a slot big enough for a full blade) and a file.

Unless it is hardened steel...

[T42]

You can pick up sets of security driver bits on the Internet for about a fiver.

[Torslanda]

Dremel-alike is almost there but for cutting 2mm steel a small angle grinder with a 1mm cutting blade would be my choice.

[Feanor]

For a slot only 5mm wide, I'd not do any cutting.
I'd do it all with a drill.

Drill a series of small pilot holes in a line, then enlarge them with increasing drill sizes till you are using a drill just a shade under the final width.
As the holes  come close to joining, a bit of gentle tilting of the drill will join the holes.
Gently gently so as not to snap the bit, which is not designed for sideways forces.
Then a file to tidy up.

[ScumOfTheRoad]

Dremel-alike is almost there but for cutting 2mm steel a small angle grinder with a 1mm cutting blade would be my choice.

I would imagine you have lots of experience with machining breast plates for Mrs Torslanda.

[ScumOfTheRoad]

Can you not get a file in there, or failing that slip a junior hacksaw blade through the slot, then put the handle on and go from there?

Good idea. I got a junior hacksaw blade in, but the two hasksaws I have dont have the facility to turn the blade round, if that makes sense.

[ScumOfTheRoad]

You can pick up sets of security driver bits on the Internet for about a fiver.

Good excuse for buying more tools! I found that there is an RS Components near me..

[ScumOfTheRoad]

I'd use hand tools - hacksaw (Abrafile blade to get a slot big enough for a full blade) and a file.

Unless it is hardened steel...

Wobbly, I've never heard of an Abrafile blade. I shall Google. Its sounds good.
Regardign the hardness of the metal, it looks standard mild steel to me. But I have had trouble drilling it with HSS bits.

[Jurek]

You can pick up sets of security driver bits on the Internet for about a fiver.

Good excuse for buying more tools! I found that there is an RS Components near me..

I noticed that the other day as well.
For reasons I cannot quite explain, I find myself drawn like a magnet, towards Bermondsey.

[ScumOfTheRoad]

Looks like Abrafile blades are no longer available.
I'm going to get a tile saw, they're six quid from Toolstation  https://www.toolstation.com/search?search=tile+saw
Not sure a tungsten carbide blade like that is intended for metal, but for six quid I can find out.

I'm quite pissed off about the Dremel-alike tool. The cutting disks just wore out as fast as I could use them - they did cut into the metal. Are there more robust disks I can buy for a Dremel?

[ScumOfTheRoad]

You can pick up sets of security driver bits on the Internet for about a fiver.

Good excuse for buying more tools! I found that there is an RS Components near me..

I noticed that the other day as well.
For reasons I cannot quite explain, I find myself drawn like a magnet, towards Bermondsey.

You must resist.. resist...
I went in and there ws a 3D printer... blokey in shop was offering the product code to me. Noooo....

[Jurek]

You can pick up sets of security driver bits on the Internet for about a fiver.

Good excuse for buying more tools! I found that there is an RS Components near me..

I noticed that the other day as well.
For reasons I cannot quite explain, I find myself drawn like a magnet, towards Bermondsey.

You must resist.. resist...
I went in and there ws a 3D printer... blokey in shop was offering the product code to me. Noooo....

Looking at Kickplatedirect's website, I think you'll find your finger plate is stainless - you'll struggle to cut that with conventional tools.
Most (but not all) stainless isn't magnetic, or only very, very mildly so.
Give it the magnet test. If it grabs, it's mild steel.

[ScumOfTheRoad]

Arse. It is indeed satin stainless steel. Jurek, do I need a lathe? And lots of other power tools? Please?

[Jurek]

Arse. It is indeed satin stainless steel. Jurek, do I need a lathe? And lots of other power tools? Please?

I'm pretty sure that RS will sell you cobalt drill bits, which will make a hole much easier in stainless than conventional HSS. At a price.
Of course you need a lathe. Doesn't everyone?

[ScumOfTheRoad]

Want  https://www.machinemart.co.uk/p/cl300m-metal-lathe/

ps. Saturday Live is talking about sheds. Paging Mr Larrington.

[Torslanda]

Still favouring the 1mm cutting disc option.

[Valiant]

Bosch multi cutter drill bits with the blue twin thread will go through it easy.

[Jurek]

Want  https://www.machinemart.co.uk/p/cl300m-metal-lathe/

ps. Saturday Live is talking about sheds. Paging Mr Larrington.

Don't mess with this stuff.
It isn't quality.
It's a recipe for disappointment after a very short period of elation.
Get a proper lathe with DRO.
Like a Myford Super 7.
Or  a Colchester Student - if you've the space.
ChrisN will be along shortly to confirm that I'm not talking complete rubbish.

[rogerzilla]

Frikkin' lasers.

[Efrogwr]

Did you use "fibre" cutting discs (they are brown)?  I've always found that they don't last; you can see them wearing away!  Diamond discs (metal and a bit sparkly) cut better and last a lot longer. They also cost a lot more.

[pcolbeck]

Want  https://www.machinemart.co.uk/p/cl300m-metal-lathe/

ps. Saturday Live is talking about sheds. Paging Mr Larrington.

Don't mess with this stuff.
It isn't quality.
It's a recipe for disappointment after a very short period of elation.
Get a proper lathe with DRO.
Like a Myford Super 7.
Or  a Colchester Student - if you've the space.
ChrisN will be along shortly to confirm that I'm not talking complete rubbish.

Stop tempting me. I always wanted a lathe. I saw a really nice Myford Super 7 on ebay just now. I don't need a lathe I really don't.

[Tim Hall]

Frikkin' lasers.

Plasma cutter FTW

[Ham]

Stainless you need to work at slow speed with lubrication. Cobalt drills will work better, but for 2mm you could get away with any. Slow. Speed. And. Lubricate.

As has been noted, there are diamond cutters for dremel,and screwfix do a set for £15 https://www.screwfix.com/p/mixed-mixed-security-bit-set-33-pieces/2840v or Toolstation for £5 https://www.toolstation.com/shop/p52910

I bought the £5 set from Screwfix years ago, and they have been fine for my purposes, although I do have specialist drivers for the small electrical sizes, the £5 set is a tad agricultural.