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How to cut aluminum sheet

Mastiff

Mastiff

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I have a jig saw, a right angle grinder, a circular saw, a sawzall and a dremel tool. What blade/attachment would folks recommend I stick on one of these to get the best cut on a sheet of aluminum? I've used the sawzall before with a generic metal blade (looks like a hacksaw) and it worked but made a ratty chipped up cut.
 
I don't have a ton of experience, but when I cut mine I used a jig saw and was surprised how well it worked. how thick is your sheet? mine was 1/8th in so if it's thinner that might be why it got jagged.

the dremmel would probably be too slow, but a grinder with a cutting wheel would probably be fine.
 
ashman said:
I don't have a ton of experience, but when I cut mine I used a jig saw and was surprised how well it worked. how thick is your sheet? mine was 1/8th in so if it's thinner that might be why it got jagged.

the dremmel would probably be too slow, but a grinder with a cutting wheel would probably be fine.
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Yeah, at least 1/8", maybe thicker. I was using it as a rigid mounting surface for electrical components.

I wasn't sure if the cutting wheel would melt the aluminum or something, or maybe just gum up. It's also hard to get straight lines, at least for me.
 
Jig saw with mid size teeth and little pressure should be perfect. big teeth will be jagged and ruff, little will gum and plug up. Angle grinder will do though
 
4X4HIGH said:
A jig saw will be your best bet. How much do you need to cut?
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Pretty easy, just cutting a small rectangle into a smaller rectangle. Maybe 8" of total cut. I'm just making a mounting surface for a small fuse panel and some relays that I will mount on the inside of the fender. Starting with a 6x12" piece from Ace.
 
in that case, I say go with the jig saw. set up a guide if you are having trouble keeping it straight, then you can clean up the edge with the right dremmel bit.
 
You guys know you arent suppose to use carborundum cut off and grinding stuff on aluminum right? It clogs the pours in the wheel, can take it out of balance and cause it to grenade, possibly in your face.

Im not saying they dont work but you should really use a blade or shear to cut aluminum and a cutter or sanding type grinding disc to work with aluminum.

Fine tooth blade on a jig saw is the ticket for sure.
 
For long straight cuts, you can use a skill saw with a good sharp carbide tipped blade. For smaller pieces, the jig saw will probably do just fine. You don't want too fine a tooth blade though as it will clog. What I use a lot for cutting smaller pieces of aluminum is a stationary bandsaw. Mine has a 10/14 tooth blade which is okay for thinner aluminum, but for thicker, say 3/16" and up, a coarser blade will work better.
 
There is a wax that is meant for aluminum cutting with abrasive type cutting tools. Basically run the blade into the wax stick and then start cutting. Reapply as needed. Keeps the abrasive pours from clogging with aluminum.

Some care must be taken as to what processes will follow the cutting as well. For instance, if it is to be welded, make sure it can be cleaned thoroughly.

Aluminum welding processes require a very clean setup.

A jig saw can work excellent. A little bit of masking tape can protect your surface from scratches created by the jigsaw base.
 
cybrfire said:
There is a wax that is meant for aluminum cutting with abrasive type cutting tools. Basically run the blade into the wax stick and then start cutting. Reapply as needed. Keeps the abrasive pours from clogging with aluminum.
/quote]


Thats good to know!
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Carbided tipped skil saw or jig saw for contouring and turning corners.
 
cybrfire said:
There is a wax that is meant for aluminum cutting with abrasive type cutting tools. Basically run the blade into the wax stick and then start cutting. Reapply as needed. Keeps the abrasive pours from clogging with aluminum.
Click to expand...

I use Boelube for saw cutting or drilling aluminium. It works great and is $5-10 IIRC. If you can find someone with a shear, that would be the best solution. Outside of that I'd use a cutoff wheel.

Just don't use a grinding wheel and anything you do will be fine.
PM me the size you want, including the thickness. I may have what you need already in my scrap bin.
 
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