cutting aluminum...

[T Diddy]

...what's everyone using?

I'm trying to make a frame and I need the edges to be somewhat tidy. Thanks in advance!
:wildone:

 

[schristi69]

abrasive cutoff chop saw, small grinder with cutoff wheel, hack saw,

 

[willybub]

if using chop saw or grinder with some kind of cutting disc try and find one made for cutting aluminum. Alot of blades tend to plug up when cutting it and melt it rather than cut it. i think a hack saw or bandsaw would be best, or plasma if you have one...

 

[antbreon]

plasmas are awsome... i have one but probably not the right tool ...they leave a rough edge..

you can use about any wood tools with a good carbide blade...for skill saw or miter box saw...diablo..red ones at home depot or lowes...

about a 16 tooth on a band saw blade..large teeth are key..

you can even use a router to round the edges...

you are correct there are grinding blades/wheels for aluminum ...huge differences...

i own a race car fabrication shop...racecarbuilders.com so i work in alot of metal..fiberglass carbon ect ect....

 

[T Diddy]

Thanks for the replies guys. In the past I've used a tile wetsaw, angle grinder, mitersaw, jigsaw, hacksaw, etc. I like the idea of the mitre box. I'm trying to figure out how to cut my U-channel so that it can be bent to a 90 degree angle...it needs to look good.

Any other thoughts?

 

[T Diddy]

I'm trying to do something like this, but prettier...it needs to bend as one piece like a rectangular wrought iron table or something.

 

[larrypoe]

finaly a section i dont feel like a moron in ..........im fairly handy around a welder or cutoff saw .....aluminum is accualy a bit of a spec of mine too ....i worked in a factory that made high end aluminum windows for years..I would use a chop saw w a abras blade myself and then just touch up the edges w a grinder. assuming of course ya dont have a bandsaw set up w a medal cutting blade that is, or a jig saw with a metal blade.. the jig would prob be a cleaner cut but the chop saw will be ok if you dont force it through too much. the bandsaw would give you a the cleanest cut. the saw i used in the factory was a carbide blade w a cooling system (sprayed a water mix on the metal) but those arent just laying around every shop :/..that sucker did cut clean though

 

[kcress]

I believe you can use any fine saw blade on a chop saw or table saw too.

 

[SC Reefaholic]

Always had best results with a fine hacksaw and miter box. then a file to clean up the edges.

 

[antbreon]

aluminum is soft enough... you all should try a regular wood band saw or table /miter box saw sometime..that is what all the guys use that make all the aluminum t tops for boats down here..the fine teeth of the metal blade acually will clog..and not work as well...just like a grinding wheel made for metal...

and for the angle 45 deg to each side...of your bend line...

 

[jkcoon]

Ditto.. if you have one available and is pretty mild aluminum, just use a power miter box and a fine tooth blade... i wouldnt make it a regular occurance but a few cuts will be fine

 

[T Diddy]

Thanks again for all of the input. I think I'll attempt this with a new metal blade on my jigsaw. Aluminum is relatively cheap, so if I screw up the next one, I'll try the mitre box.

Thanks again,
T

 

[zigzag1]

aluminum is soft enough... you all should try a regular wood band saw or table /miter box saw sometime..that is what all the guys use that make all the aluminum t tops for boats down here..the fine teeth of the metal blade acually will clog..and not work as well...just like a grinding wheel made for metal...

and for the angle 45 deg to each side...of your bend line...

+1 to this. I recently put in a new set of shower doors and had to trim the top and bottom rails. My miter chop saw with a med/fine wood cutting blade made a fast and neat job of it. Aluminum is pretty soft and cuts more like wood.

 

[txmike2]

if you have to go back to the chop saw load the blade up with some wax it will help it from cloging up with the aluminum.I have used Ashburn wax sticks for years for this kind of thing but realy any wax should do.

mike

 

[jkcoon]

if you have to go back to the chop saw load the blade up with some wax it will help it from cloging up with the aluminum.I have used Ashburn wax sticks for years for this kind of thing but realy any wax should do.

mike

Excellent tip... will put tha tone in my back pocket and use it next time I have clogging issues.