Best method to cut a steel barrel

[HandOverFist]

I recently had a thought about cutting a steel barrel lengthwise to use as a fuel tank on the back of a truck. I would be cutting the 55 gallon barrel around the 50-70% mark if that makes sense.

My question is what tool would net me the cleanest, straightest cut? It will be welded to a bulkhead (steel plate) to create a fuel tank and I need the best edges I can manage. Would a plasma cutter along with clamped straight edges be viable?

Just came across this video... https://youtu.be/VH9-FO4-17Q Seems to work really well if one took the time to build the jig.

 

[Toad]

This is just me personally, but I would feel more comfortable using a cut off wheel since my plasma skills suck!

Toad

 

[HandOverFist]

I don't know if I can cut a straight line with a cutoff wheel, plus that is a lot of cutting with a die grinder. I'm a little leary anyway about cutting on a barrel...fill with water? I was thinking drag a plasma head along a straightedge?

 

[DozerII]

4.5 inch angle grinder with an .045 cutting disc is the smoothest fastest. Make a series of marks around the barrel, then use some 2"masking tape to connect the marks and follow the edge with the cutting disc.

 

[redidbull]

I bought one of these years ago and works great. I never ran it down a straight edge but can't see why you couldn't. Jim
https://www.harborfreight.com/power-tools/grinders-sanders/stands-accessories/safety-guard-for-angle-grinders-61680.html

 

[Tripper]

I bought one of these years ago and works great. I never ran it down a straight edge but can't see why you couldn't. Jim

Thanks... I'm definitely gonna get one of those!!! I've seen people that can use a plasma & make some amazing parts... I am not one of those people! [ddd

BoB

 

[HandOverFist]

Thanks for all the replies guys. I am neither a pro with a welder or plasma cutter myself...just looking for any options that will make life easier when it comes time to weld/put this all together.

 

[05snopro440]

The angle grinder would be my choice, it's a lot easier to keep it straight.

 

[Bamamav]

For something that big I use a Skil saw and either a metal cutting blade or a abrasive blade.

 

[HandOverFist]

I saw one of these mentioned earlier on the forum... https://www.eastwood.com/eastwood-mini-metal-saw.html Looks like it would be perfect for something like this.

 

[eyesore]

I saw one of these mentioned earlier on the forum... https://www.eastwood.com/eastwood-mini-metal-saw.html Looks like it would be perfect for something like this.

Pretty expensive tool to cut a drum in half! [S

iSore

 

[HandOverFist]

Pretty expensive tool to cut a drum in half! [S

iSore

If I were to buy one it would get used for more than that. Looks like it would beat the pants off any cut-off wheel/die grinder which is all I have ever had to work with up to this point other than a sawzall to cut metal.

 

[donsrods]

I bought one of these years ago and works great. I never ran it down a straight edge but can't see why you couldn't. Jim
https://www.harborfreight.com/power-tools/grinders-sanders/stands-accessories/safety-guard-for-angle-grinders-61680.html

That looks like a great idea. Cutters that have spinning cut off wheels scare the heck out of me. I can always see them exploding in my face !

Years ago, I had a 12 inch chop saw with a cutting blade on it. One day I turned it on, bent down to pick up something from under the bench, and the blade exploded into shrapnel, some of it embedding in the ceiling ! If I had been standing up, it would have taken my head off.

Dan cuts everything with one of those cut off wheels, he is good at it and takes his time, but I stay away from using one.

 

[phil cottingham]

I have had good luck with a jig saw and metal cutting blade. It is steadier than a disc grinder.

 

[offroadrolls]

I don't do it often but sometimes it's the best way I can figure. I have a circular saw aka skill saw that's old enough that the body of it is made of some sort of metal. I put about a 7" abrasive blade in it and run it just like I'm ripping a piece of plywood. It works great! Thinking about your barrel project, I think it would probably work well. It's relatively easy to get a nice straight cut, especially if you set up some sort of fence to run the saw along. Where ear protection for sure.

 

[HandOverFist]

Thanks for all the suggestions! I have the barrel sanded down to bare metal and the rest of the metal for the project ordered...going to have to make a decision soon and take the plunge. [

 

[HandOverFist]

Mission accomplished and I did'nt blow myself up lol! After playing with the plasma cutter I determined that method was not going to give me the desired edge I needed. I went ahead and bought one of those Eastwood mini-metal saws...more than worth the investment. No way I could have done as clean a job with a grinder/cut-off wheel. Wish I have had one of these saws years ago.