Cutting aluminum?

[Corey123]

What's everyone use for cutting thicker (1/8-3/16") aluminum? I've tried scroll saws, hand saws and hack saws, but they all seem to not work very well. Any suggestions? Thanks guys!

[BigSki]

Originally Posted by Corey123

What's everyone use for cutting thicker (1/8-3/16") aluminum? I've tried scroll saws, hand saws and hack saws, but they all seem to not work very well. Any suggestions? Thanks guys!

you should be able to cut those thicknesses with each tool that you listed, what is the tooth count on the blades that you are using? ( TPI is what it's called) and you need to use a SLOW speed if using a power tool, something in the neighborhood of 300-500 RPMs max, otherwise all you end up doing is making heat and dulling the blade.

[Erin]

I use a hack saw and coping saw depending on cut. Then file to tolerance. A good file goes a long way with aluminum if cutting by hand.

[sim]

I have good luck with a hacksaw.
You want...
1. A decently new blade (still straight and sharpish)
2. Some thin oil on the blade
3. At least 3 teeth across the thickness of the piece (so at least 24 tpi for 1/8")

[War Pig]

I use a band saw with a 14 to 18 tpi blade. If I'm cutting alot of aluminum, I run a bar of soap into the blade for a few seconds...........it keeps the teeth from loading up with aluminum. Plus it smells spring fresh!

[bob1961]

straight cuts or even angled cuts off a straight side i use my dewalt 12" miter saw i use for wood....makes a very nice clean cut in alum up to 1" x 7/8" bar stock, just need to go slow to where i get alum dust and no big chips....i have cut stuff from 1/16" thick to 1" thick with no problems .......bob

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[Duuuuuuuude]

Originally Posted by Erin

I use a hack saw and coping saw depending on cut. Then file to tolerance. A good file goes a long way with aluminum if cutting by hand.

[Crawling Calvin]

Originally Posted by sim

I have good luck with a hacksaw.
2. Some thin oil on the blade

I love "charcoal lighter fluid." Any old brand works, get the cheapest you can. 2-3 drops/side of the blade goes a LONG way to making aluminum cut easy and not leave that nasty "rough" finish behind from the blade sticking. Just obviously be careful using it because after a lot of cutting fumes can form and... you go just a wee bit nuts

Other than that, they hit up all the good points. Can't stress enough on sharp blades...

[pppowercrawl]

I use 1mm thick cutoff wheels and a 5" angle grinder, works great on 8mm thick aluminium.

If I'm cutting alot of aluminum, I run a bar of soap into the blade for a few seconds...........it keeps the teeth from loading up with aluminum. Plus it smells spring fresh!

I've also heard you can use WD-40, I know it works for sanding but never had to use it for cutting.