I just got frustrated trying to use my 14" Milwaukee abrasive cutoff saw to cut a 45 degree angle on 1 inch by 1 inch steel bar. The cut length is around 1.4 inches, and that seems to be more or less the limit with abrasive cutoff saws, in my experience. The blade seems to get duller and duller (or at least it cuts more and more poorly) with longer cut lengths in steel. I made it through two cuts, and bogged down on the third cut. As long as the cut length is half an inch or less, the abrasive saws work well.
I know that several people around here promote using a Skil saw or other worm drive wood circular saw for cutting steel, using Morse Metal Devil or Tenryu Steelpro steel cutting blades. How will this perform on cutting thick steel, such as my 1 inch by 1 inch bar with a 45 degree angle cut? I have an oxy-acetylene torch, but the cuts are really rough, even if I use an angle iron as a guide. Or is there some other alternative that doesn't cost hundreds or thousands of dollars? I don't have room for a cold saw or bandsaw, unfortunately. What are the practical limits of the Skil saw for cutting steel?
Richard