Best power metal-cutting & chop saws according to redditors

Because the safety guards are shaped differently for cutting and grinding, a cutoff wheel in a bench grinder is potentially deadly. Even if that is really what he wants, please do not get them for him. You might consider getting him a cutoff saw. Here are a couple models that are decent:
https://smile.amazon.com/PORTER-CABLE-PCE700-Amp-Chop-Saw/dp/B00NI2CF28
https://smile.amazon.com/Makita-2414NB-14-Inch-Portable-Cut-Off/dp/B0000223J5

I'd disagree. I think you'd be much happier spending a bit more money on a cold cut chop saw like this: https://www.amazon.com/DEWALT-DW872-14-Inch-Multi-Cutter-Saw/dp/B0000302QS

It's more precise and you get much cleaner cuts.

I've got one. It's badass, say good bye to all the abrasive shit and sparks flying everywhere.

Mine is an Evolution saw + blade.

I think this is the one I have:

https://www.amazon.com/Evolution-Power-Tools-RAGE3-Multipurpose/dp/B0030M2TCC

I bought the steel purpose blade and it came with the multi-purpose. The steel one is blue color, so it could very well be the one being used in the video.

Makita LC1230 12" Cold cutting metal saw. Not a true cold saw, but pretty damned close. I've bought the lower end portable band saws and they're fine for rough cuts on light sock - but if you need to cut up a batch of angle iron or steel for welding projects - and you want consistent cuts that don't take all day - you'll LOVE one of these saws. I've had mine for a year and the original blade is still going strong.

http://www.amazon.com/Makita-LC1230-12-Inch-Metal-Cutting/dp/B00004YOLV

I'd use a cutoff saw, even a harbor freight one for 110 cuts.

https://www.amazon.com/DEWALT-D28715-14-Inch-Quick-Change-Chop/dp/B000HHWWES/ref=sr_1_1?ie=UTF8&qid=1500131411&sr=8-1&keywords=dewalt+d28715

Speed square + clamp of your choice + cordless saw with metal-cutting blade.

Or use a speed square to mark your cut with a pen and then freehand cut with an angle grinder. Following a line is a lot easier than just winging it.

The answers seem to depend on what you're using the rods for, and what the quality of cut needs to be. With the bolt-cutters, you were ending up with a pinched cut. If that was acceptable, any other method would probably work fine too.

Is there any other metal work that is done, that would benefit from also using any tool purchased for this task? Or would something dedicated to this job be an acceptable cost?

A harbor freight portable bandsaw is rather cheap, would give a reasonable cut at a reasonable speed. You could also pick up a cheap 7.5" or 8 1/4" miter saw ($60-130), and get a metal cutting blade for it ($50-100). I tried a wood blade with perpendicular teeth, and was able to cut 1/4" steel fine too; it'd certainly work on copper. I'll tell you before others correct me, those aren't intended for that sort of work, so for business purposes they'd be entirely the wrong thing to use. That said, I expect it'd work.

Or for a tool intended for that purpose, $150 gets you a 7-1/4" metal cutting chop saw with tungsten carbite teeth, so no gumming up an abrasive blade with the soft copper. Under $20 replacement blades too. Much cheaper than even my miter saw idea above, so we'll ignore that.

i bought this on woot, and looks like amazon has a great deal going on right now. used it for my last project and it was awesome.

http://www.amazon.com/Scheppach-M90700-4-inch-Plunge-Connector/dp/B009AQ81FQ

A chop saw works great. They’re insanely fast.


PORTER-CABLE PCE700 15 Amp Chop Saw, 14" https://www.amazon.com/dp/B00NI2CF28/ref=cm_sw_r_cp_api_i_9OvnDb6KH8BZ4

Sounds like a job for an abrasive chop saw, like this one:

https://www.amazon.com/DEWALT-D28710-14-Inch-Abrasive-Chop/dp/B00551DJBQ

Metal Drop saw: https://www.amazon.com/PORTER-CABLE-PCE700-Amp-Chop-Saw/dp/B00NI2CF28/ref=sxin_2_ac_d_rm?

This.https://www.amazon.com/PORTER-CABLE-PCE700-Amp-Chop-Saw/dp/B00NI2CF28/ref=sr_1_3?s=power-hand-tools&ie=UTF8&qid=1474605155&sr=1-3&keywords=chop+saw

I've seen people have good luck getting a metal cutting blade for a chop saw, but they're rather expensive and you risk burning out your saw.

I think you're best bet is to buy a cutoff saw on craigslist. Shoot for $75-$90. You'll probably use two disks at $5 a pop. The 45's are tough to cut on those, but you dont have to if you dont want to.
I picked one up locally for $100 and I'm happy with it.
You can also rent them for the day, but good luck getting all your cuts and never needing it again.

The best method if you have the cash is a horizontal band saw. You can get an alright one from HF for $170, but it takes up some floor space.

You'll for sure need an angle grinder and a boat load of disks.
You're sawzall likely won't help you any.

Here's where I'm at on mine. http://imgur.com/XpSs4
Prior to this I've never had any experience with metal working, welding, sweating (made a CFC), etc.
A lot of learning came from the prestigious University of Youtube.

I've been considering the Evolution Rage 3 for awhile now, it gets pretty great reviews and can cut wood, aluminum and even steel.

I am showing 242.95 Damn saws are expensive.. Doubt my 73 dewalt miter box would handle cutting thick metal..

Were you potentially thinking of this one: http://smile.amazon.com/Evolution-Power-Tools-RAGE3-Multipurpose/dp/B0030M2TCC/ref=sr_1_1?ie=UTF8&qid=1419187986&sr=8-1&keywords=rage+3&sa-no-redirect=1

grab one of these http://www.amazon.com/Evolution-Power-Tools-RAGE3-Multipurpose/dp/B0030M2TCC/ref=sr_1_1?ie=UTF8&qid=1419187986&sr=8-1&keywords=rage+3

150, and burr free cuts. You can even use it for wood later.

haha, ok apparently I misheard the person who helped, or just made up a name, it's king of like this but a sturdier handle and a nice blade, I think I saw something akin to it at Home Depot the other day too, this is an idea, it was different though(brand, shape of handle and all), but hefty and nice:

https://www.amazon.com/Neiko-RIDGE30065A-Inlet-Pneumatic-Saber/dp/B000IU0CSW/ref=zg_bs_1026922_6?_encoding=UTF8&psc=1&refRID=71FHJDN1XYT0S0SWTVWG

and bingo: we need to get the new one in still, but working on that!

That's how they do it in the field, as far as oilfield and fencing go (which is 99.9% of pipe use).

I have a Milwaukee 14" carbide dry saw. It can cut perfect angles. In fact, it leaves a machined finish, and straight from the factory is dead nuts in every aspect of the cut. I can cut 4" sch40 in around 30 seconds and 6" sch40 in around 50-60 seconds. Take a look at them, if you can afford it, they're great.

Never EVER EVER just have one cutting tool. I rarely cut 4" ANYTHING, but all my equipment is capable of it.

Main saws: Milwaukee 14" dry saw. Street price is around $500
http://www.amazon.com/Milwaukee-6190-20-14-Inch-Cutoff-Machine/dp/B00023S336

Milwaukee 8" dry saw (handheld): Street price $350
http://www.amazon.com/Milwaukee-6370-21-8-Inch-Cutting-Circular/dp/B0000WUQI4/ref=pd_sim_hi_6

HF 4"x6" bandsaw I've put hours into making perfect. I use this one for thick thick pieces, hardened steels, and larger aluminum sections of I have time. The carbide saw cuts aluminum ridiculously fast, but needs a different blade + lube. If I'm too lazy to change blades and baby sit, I throw it in the bandsaw.

I also have a big table I built for it and use it as a vertical bandsaw for precise cutting of smaller sections and scroll saw use.

Milwaukee BIG sawzall

Milwaukee porta-band bandsaw (jigsaw)

Mikwaukee m12 jigsaw

grinders with zip disks

Plasma

Torches oxy propane and oxy ace

and 2 regular chop saws

https://www.amazon.com/Makita-LC1230-12-Inch-Metal-Cutting/dp/B00004YOLV

Buy this and you can thank me later.

This thing is tremendous. It looks like a chop saw, but it uses a carbide-tipped sawblade instead of an abrasive disc. Cuts steel in seconds, leaves a clean edge, doesn't heat up the stock like an abrasive saw.

You need a metal cutting circular saw. They are low RPM and high torque. The Harbor Freight 5 3/8" one does not work as you cannot find a blade that is fine enough for Aluminum anywhere. You need a 7 1/4" 60 tooth blade at least.

This saw on e-bay should work. Use google to find your blade.

http://www.ebay.com/itm/metal-cutting-circular-saw-/151348856713?pt=LH_DefaultDomain_0&hash=item233d184789

Frankly, if you have the money, this 14 inch Multi Cutter with a 100 tooth blade will do the job nicely.

http://www.amazon.com/DEWALT-DW872-14-Inch-Multi-Cutter-Saw/dp/B0000302QS/ref=lp_1026922_1_5?s=power-hand-tools&ie=UTF8&qid=1405138745&sr=1-5

Finish is outstanding with either tool, when you use the right blade.