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Cutting metal

It kind of depends on how much cutting you need to do. I've used a saber saw with a metal-cutting blade for small jobs in fairly thin steel.
 
If you have very much to cut it would be easier if you would invest in a sheetmetal nibbler. It would have to be a heavier model to handle at least 14 gauge. If you are only cutting a few pieces and the parts are large enough I might use a metal cutting blade on a jig saw.
 
Not wanting to argue, but why is a saber saw "the worst"? Worse than tin snips or hacksaw? Just curious about the problem I've avoided. I agree a plasma cutter is great, but the cost is huge compared to simpler tools if you have to buy one from scratch.
 
A friend of my oldest son works in a robotics shop. He told me about "water jetting." I've never heard of it, but he said it's very reasonable,as far as price goes. (Water mixed with abrasive media in a precision cut) If your near a larger city, you might check into it.
 
plasma cutter, water jet, or simple way out jigsaw clamp steel to plywood and go at it. done lots times with jigsaw but you must hold it down steady.
 
Can you drill a hole, like quarter inch or bigger, just outside of the corner, giving you a new angle of attack?
 
If you have an air supply you can use a die grinder with a steel cutting wheel should say on it its for metal. You could even use these double cut rotary files they even come in a 1 inch dia. size just make sure the cutting edge on the rotary files looks like the picture these are for steel.
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45891.jpg

Just a thought Byron
 
You didn't say how big the pieces are or how many, or how tight the curves are if any. I like a bandsaw or saber saw. Don't have a plasma cutter. Could use a torch.
 
My "go-to" tool is my 4 1/2" angle grinder for cutting steel. You didn't specify the shape so it's hard to tell what the "best" tool available in a home shop would be. Dremel maybe.
 
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