Re: Building a under bus storage box with an old locker
for cutting sheet metal, i also like to use a standard 7 1/4" circular saw like you'd normally use for cutting 2x4's or plywood. I put a metal cutting abraisive blade on the saw. I find this to be one of the easiest methods for cutting a straight line in sheet metal.
like mentioned above, the skinny abrasive cut off blade on an angle grinder is also a great solution.
I'm all about safety 3rd, but with either of the above methods, don't for get to wear ear, eye, and breathing protection. Lots of small glowing red hot flying metal particles, dust, etc flying around and it is surprisingly loud!
I have certianly used a sawz-all and have the same problem of not being able to cut a straight line. Ugly cuts can be made with a torch, or even an arc welder with the heat turned most of the way up...not something you're gonna do on this project, but just thought i'd throw those out there. I like cutting things with my arc welder when neatness doesn't matter. I've even cut through 1/2 inch plate. someday i want to own a plasma cutter......
Quis custodiet ipsos custodes (who will watch the watchmen?)