Neil,

A band saw sure is nice. A wide blade and a narrower one, even on a woodworking band saw does almost 75% of your aluminum cutting. Baked speed might be an issue if you want to cut steel, but you could make it work.

A cheap chop saw, yes I'm looking at you canadian tire, with a neg rake carbide toothed blade is perfect for the rest of the aluminum cutting.

If you do a lot of steel, then a dry cut saw works well. Princess auto has one that has lasted pretty well in our shop. Throws chips, as does the aforementioned CT chop saw, but it is a lot less messy than an abrasive cut off saw.

Don't worry about shears. You can't afford the ones that you want :)

And heavy steel cutting? Your oxy acteylene cutting torch is the boss.

All other cuts are probably best left to waterjet or laser cutting (or plasma). 

Alistair

> On May 2, 2014, at 9:46 AM, Neil N <musomuso@GMAIL.COM> wrote:
> 
> Hi all.
> 
> Finally signed a lease for a new Vanagon "shop" space. Reasonably
> sized: 21' x 18' x 8.x' high garage. I'm allowed to MIG weld, cut
> metal, but ventilation may be an issue.
> A cut-off wheel in angle grinder throws a lot of dust.
> 
> Do budget oriented metal shears generally last long enough for NON
> commercial use?
> eg: http://www.kmstools.com/magnum-12-hand-shear-3035
> The thickest metal I work with so far, is 1/8" though I wonder if a
> shear like that would actually cut it.
> What about cutting 1.5" or 2" box steel?
> 
> I don't have an O2-acetylene set up.
> 
> Would a band saw suffice for cutting sheet, plate, box and tube material
> but not throw as much dust as a cut-off wheel?
> Other tool suggestions are welcome! I would not run a compressor.
> 
> I don't foresee a lot of fabrication. And since 110 VAC to garage is
> on a shared breaker, this may negate any real future fabrication work
> beyond cutting and tacking parts in place. Still. It would be fun to
> learn of things like intake manifold alterations, copying diesel
> vanagon carriers, etc.
> 
> Thanks much,
> 
> Neil.
> 
> 
> 
> --
> Neil n
> 
> Blog: tubaneil.blogspot.ca
> 
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> 
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> 
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> 
> http://tinyurl.com/d7gd5ej