Cutting cast iron

[Dave Plowman (News)]

I posted some time ago about fitting a cast iron fireplace into an
existing marble surround. The correct way of doing it would be to remove
the surround - but this is a great deal of work and I'm worried about
breaking it. The other way would be to trim the edges off the insert so it
can be fitted with the surround in place. (it will be purely decorative)
It's about 1/2" thick. Obviously, I suppose, an angle grinder would cut it
but they tend to terrify me ;-)

Any safer way of doing it? Could I take it somewhere to have it done -
perhaps with a plasma or whatever cutter?

--
*Why is "abbreviated" such a long word?

Dave Plowman da...@davenoise.co.uk London SW
To e-mail, change noise into sound.

[Phil]

On 08/01/2013 13:33, Dave Plowman (News) wrote:
> I posted some time ago about fitting a cast iron fireplace into an
> existing marble surround. The correct way of doing it would be to remove
> the surround - but this is a great deal of work and I'm worried about
> breaking it. The other way would be to trim the edges off the insert so it
> can be fitted with the surround in place. (it will be purely decorative)
> It's about 1/2" thick. Obviously, I suppose, an angle grinder would cut it
> but they tend to terrify me ;-)
>
> Any safer way of doing it? Could I take it somewhere to have it done -
> perhaps with a plasma or whatever cutter?
>

Reciprocating saw, or even a jigsam with a metal cutting blade. Time is
on your side :-)

[Phil]

Oops, that 'w' is in upside-down ^

[newshound]

I think I would go with an angle grinder personally. One problem with
this sort of cast iron is that it is quite likely to contain nasty hard
slag inclusions. These are more likely to make a reciprocating saw
"kick" than a grinder. If you have a good flat surface to run a jigsaw
on that might be OK (variable speed jigsaws are fairly easy to control).

With a grinder, start with narrow, flat cutting disks and cut as close
to size as you can. If you need to "trim" afterwards, use the thick
dished grinding disks. It's not going to be a quick job.

I suspect that someone who knows what they are doing might be able to
do it with a gas axe or plasma cutter, but I would be worried about
cracking it through differential thermal expansion. And you would
probably still need to clean up with a grinder.

[newshound]

On 08/01/2013 17:15, newshound wrote:

The other specialist method which I forgot to mention is electro
discharge machining (EDM) which would definitely work. ISTR reading
about people who have DIYed this in the States, although I wouldn't
recommend this for just one job!. You might find a workshop who would
take on the job.

[The Natural Philosopher]

+1.

This time an angle grinder IS the correct tool.


--
Ineptocracy

(in-ep-toc’-ra-cy) – a system of government where the least capable to
lead are elected by the least capable of producing, and where the
members of society least likely to sustain themselves or succeed, are
rewarded with goods and services paid for by the confiscated wealth of a
diminishing number of producers.

[Frank Erskine]

It's ALWAYS the correct tool...

--
Frank Erskine

[Dave Plowman (News)]

In article <kchpgk$e8q$1...@news.albasani.net>,

The Natural Philosopher <t...@invalid.invalid> wrote:

> This time an angle grinder IS the correct tool.

Yeh - but I'm terrified of them. ;-)

--
*According to my calculations, the problem doesn't exist.

[Tim Lamb]

In message <530b0ab...@davenoise.co.uk>, "Dave Plowman (News)"
<da...@davenoise.co.uk> writes

>In article <kchpgk$e8q$1...@news.albasani.net>,
> The Natural Philosopher <t...@invalid.invalid> wrote:
>> This time an angle grinder IS the correct tool.
>
>Yeh - but I'm terrified of them. ;-)

Invite Frank along to do it?
>

--
Tim Lamb

[Phil]

On 08/01/2013 23:09, Dave Plowman (News) wrote:
> In article <kchpgk$e8q$1...@news.albasani.net>,
> The Natural Philosopher <t...@invalid.invalid> wrote:
>> This time an angle grinder IS the correct tool.
>
> Yeh - but I'm terrified of them. ;-)
>

If you have the time & fancy getting fit you could even do it with a
hacksaw. Blade rotated through 90 deg for long cuts, get a blade with
the right TPI for the thickness to be cut (approx 4 teeth in the cut for
most cast iron).

Phil.

[Dave Plowman (News)]

In article <kcjetj$e6o$1...@dont-email.me>,

Might give the jigsaw way a try. Are there special blades for cast iron?
Any lubricant help?

--
*You! Off my planet!

[Phil]

On 09/01/2013 10:30, Dave Plowman (News) wrote:
> In article <kcjetj$e6o$1...@dont-email.me>,
> Phil <philip_barto...@yahoo.com> wrote:
>> On 08/01/2013 23:09, Dave Plowman (News) wrote:
>>> In article <kchpgk$e8q$1...@news.albasani.net>,
>>> The Natural Philosopher <t...@invalid.invalid> wrote:
>>>> This time an angle grinder IS the correct tool.
>>>
>>> Yeh - but I'm terrified of them. ;-)
>>>
>> If you have the time & fancy getting fit you could even do it with a
>> hacksaw. Blade rotated through 90 deg for long cuts, get a blade with
>> the right TPI for the thickness to be cut (approx 4 teeth in the cut for
>> most cast iron).
>
> Might give the jigsaw way a try. Are there special blades for cast iron?
> Any lubricant help?
>

Just coarser than normal metal cutting blade for a thick cut, no lube
for cast iron.

[mark]

"Dave Plowman (News)" <da...@davenoise.co.uk> wrote in message
news:530ad5f...@davenoise.co.uk...

>I posted some time ago about fitting a cast iron fireplace into an
> existing marble surround. The correct way of doing it would be to remove
> the surround - but this is a great deal of work and I'm worried about
> breaking it. The other way would be to trim the edges off the insert so it
> can be fitted with the surround in place. (it will be purely decorative)
> It's about 1/2" thick. Obviously, I suppose, an angle grinder would cut it
> but they tend to terrify me ;-)
>
> Any safer way of doing it? Could I take it somewhere to have it done -
> perhaps with a plasma or whatever cutter?
>
>

A 9" angle grinder with a diamond blade will do this job in under 5 mins.

I would paint a thick white line down the edge to be cut. When dry use a
thick marker pen to mark the line of cut. It will be hard to see if you mark
direct on to the cast. Or, if it will stick use masking tape to receive the
marked line.

mark

[Dave Liquorice]

On Wed, 09 Jan 2013 10:30:06 +0000 (GMT), Dave Plowman (News) wrote:

>> ... get a blade with the right TPI for the thickness to be cut (approx

>> 4 teeth in the cut for most cast iron).
>
> Might give the jigsaw way a try. Are there special blades for cast
> iron? Any lubricant help?

Metal cutting blade. B-) Note the comment above about the TPI, that's a
minimum and is a good rule of thumb for cutting many materials. Don't
really know about a lubricant, a spot or two of light oil won't harm
though.

--
Cheers
Dave.

[Dave Plowman (News)]

In article <nyyfbegfubjuvyypb...@srv1.howhill.co.uk>,

Dave Liquorice <allsortsn...@howhill.com> wrote:
> On Wed, 09 Jan 2013 10:30:06 +0000 (GMT), Dave Plowman (News) wrote:

> >> ... get a blade with the right TPI for the thickness to be cut
> >> (approx 4 teeth in the cut for most cast iron).
> >
> > Might give the jigsaw way a try. Are there special blades for cast
> > iron? Any lubricant help?

> Metal cutting blade. B-) Note the comment above about the TPI, that's
> a minimum and is a good rule of thumb for cutting many materials.

I've got a variety of jigsaw blades, but don't remember any being marked
as for cast iron. Although those 'diagrams' showing what they can be used
for might as well be in Russian. ;-)

> Don't
> really know about a lubricant, a spot or two of light oil won't harm
> though.

--

*Save the whale - I'll have it for my supper*

[Phil]

On 09/01/2013 12:46, Dave Plowman (News) wrote:
> In article <nyyfbegfubjuvyypb...@srv1.howhill.co.uk>,
> Dave Liquorice <allsortsn...@howhill.com> wrote:
>> On Wed, 09 Jan 2013 10:30:06 +0000 (GMT), Dave Plowman (News) wrote:
>
>>>> ... get a blade with the right TPI for the thickness to be cut
>>>> (approx 4 teeth in the cut for most cast iron).
>>>
>>> Might give the jigsaw way a try. Are there special blades for cast
>>> iron? Any lubricant help?
>
>> Metal cutting blade. B-) Note the comment above about the TPI, that's
>> a minimum and is a good rule of thumb for cutting many materials.
>
> I've got a variety of jigsaw blades, but don't remember any being marked
> as for cast iron. Although those 'diagrams' showing what they can be used
> for might as well be in Russian. ;-)
>
>> Don't
>> really know about a lubricant, a spot or two of light oil won't harm
>> though.
>

http://www.uk-jigsawblades.co.uk/contents/en-uk/d4_Bosch-Jigsaw-Blades-for-Metal.html

Ones for thick stainless/inox ought to do pitch/set/rake - wise.

[Andy Dingley]

On Tuesday, January 8, 2013 1:33:10 PM UTC, Dave Plowman (News) wrote:
> Obviously, I suppose, an angle grinder would cut it

Only sensible way. CI doesn't like plasma, it's too heavy to easily pass it through a bandsaw and reciprocating saws leap around all over the place. Biggest diameter possible for the disk cutter gives the straightest cut.

[Jim K]

On 9 Jan, 10:12, "mark" <m...@reepham2003.force9.co.uk> wrote:
> "Dave Plowman (News)" <d...@davenoise.co.uk> wrote in messagenews:530ad5f...@davenoise.co.uk...

or white "tippex" in a pen type dispenser will draw a nice white line
2 or 3mm wide straight onto the CI

Jim K

[slinksbyj...@gmail.com]

Hi Dave,
Jane here, I was just googling this as I have exactly the same issue - I know it was three years you posted this but what did yu do and how did you get it to fit?
Any advice would be a great help.
Thank you!

[Dave Plowman (News)]

In article <0b64c971-989c-45a7...@googlegroups.com>,

<slinksbyj...@gmail.com> wrote:
> On Tuesday, 8 January 2013 13:33:10 UTC, Dave Plowman (News) wrote:
> > I posted some time ago about fitting a cast iron fireplace into an
> > existing marble surround. The correct way of doing it would be to
> > remove the surround - but this is a great deal of work and I'm worried
> > about breaking it. The other way would be to trim the edges off the
> > insert so it can be fitted with the surround in place. (it will be
> > purely decorative) It's about 1/2" thick. Obviously, I suppose, an
> > angle grinder would cut it but they tend to terrify me ;-)
> >
> > Any safer way of doing it? Could I take it somewhere to have it done -
> > perhaps with a plasma or whatever cutter?

> Hi Dave, Jane here, I was just googling this as I have exactly the same
> issue - I know it was three years you posted this but what did yu do and
> how did you get it to fit? Any advice would be a great help. Thank you!

Can't really help as I gave up the idea. Sold the insert for a decent
price and went for plan B. ;-)

--
*Why do psychics have to ask you for your name? *