Cutting aluminum sheet

[Skyking1992]

I have a 4 ft by 12 ft piece of 7075 T6 alcald aluminum .063 that I need to cut into smaller pieces for a project. Any suggestions on how to cut this? I could use a metal cutting blade or an abrasive blade in my circular saw. I have a small jig saw, but that seems like it would be really slow. Any ideas?

Thanks,
Skyking1992

 

[sublimate]

http://www.amazon.com/gp/product/B00004RH4L/?tag=atomicindus08-20

 

[NUTTSGT]

I'd guess that it could be sheared ? Is there anybody local that can shear it ? You might have to load it up and pay a charge but would probably save you some headache.

 

[Strouty]

You can use any carbide tipped blade to cut aluminum with any skill saw. I am not sure how that thickness will work, but it would be worth a shot.

 

[A_Pmech]

60 thou is a little thin to try with a skil saw unless you're very careful and use a zero clearance foot.

I'd use a nibbler.

 

[tcianci]

Your best bet other than a shear is a fine tooth carbide blade on a table saw. Don't use an abrasive cut off wheel on nonferrous metal. If you're stuck with a circular saw, cut cover the sheet with a thin sheet of sacrificial plywood and have at it.

 

[lonestarky]

Aircraft shears or tin snips available at any hardware store, nibbler will be faster. You may be able to cut it if it's on a piece of 2" thick closed cell foam insulation. Any carbide blade will do it, but higher tooth count will grab less. You may also be able to run a std 60 tooth non carbide blade backwards iirc.

Just remember to wear gloves and eye protection. AL chips are nasty, and they'll be everywhere.

Sent from my XT1254 using Tapatalk

 

[Alchymist]

http://www.harborfreight.com/14-gauge-4-amp-heavy-duty-metal-shears-68199.html

 

[A_Pmech]

cover the sheet with a thin sheet of sacrificial plywood and have at it.

Smart!

 

[Strouty]

That was my fear, but adding the plywood is brilliant.

 

[no704]

Plywood blade on circ saw.
But install the blade backwards.

 

[csp]

Plywood blade on circ saw.
But install the blade backwards.

Not on 0.063"!

No need to install the blade backwards with aluminum either, if it was thick enough to use a circular saw without a backer.

 

[gahrajmahal]

Sounds like an excuse to buy a new tool!

I have a Kett shear I bought back when I installed sunroof's. Works great for body work, does not twist the edge like scissors type snips.

http://www.kett-tool.com/product.php?cat_name=KD Double-Cut Shears

 

[Skyking1992]

Thanks for the ideas. 7075 T6 seems like some pretty tough stuff. I'll let you know what I find.

Skyking1992

 

[JKady]

Double cut shears would be my choice. My buddy skinned out a rock buggy with old construction signs which are hard/brittle like 7075, we did the whole job with double cuts and a grinder with a flap wheel, came out mint and the shears made easy work.

 

[drmarkr]

http://www.harborfreight.com/14-gauge-4-amp-heavy-duty-metal-shears-68199.html

Buy the Kett if you want to spend more money, I suppose.

I have the pneumatic version that HF carries. They would handle this almost like butter....I use it regularly on R panels and on perforated steel(22 ga/.031 thick).

http://www.harborfreight.com/air-tools/specialty-air-tools/pistol-grip-air-shears-98580.html


MR

 

[MushCreek]

If you're going to cut it with a circular saw, which is what I would do, wear hearing protection. It will be really, really loud.

 

[readhead]

Just curious about what you are doing with the material. Are you using it because it was free? If you need to form it things may not go well. You could go to a local sheet metal shop and have them supply and shear all the material.

 

[stimpy]

If you're going to cut it with a circular saw, which is what I would do, wear hearing protection. It will be really, really loud.

just as loud as cutting plywood .... I cut pistons in half on rods all the time , and its not loud ,


also if you do the plywood sandwich make sure you wax or soap the blade up on both sides so it will not stick ... we cut patch panels for semi trailers this way
and to locate the sheet we use 3m spray adhesive ( just a light coat in strips and then solvent wash it off . ,

 

[MJD1]

Lay the aluminum sheet on foam board and use a regular carbide tipped blade. The foam board will keep the aluminum very secure and if you set the blade shallow, there will be no grabbing or vibration.

 

[MarkWilliams60]

I have a 4 ft by 12 ft piece of 7075 T6 alcald aluminum .063 that I need to cut into smaller pieces for a project. Any suggestions on how to cut this? I could use a metal cutting blade or an abrasive blade in my circular saw. I have a small jig saw, but that seems like it would be really slow. Any ideas?

Thanks,
Skyking1992

The main question is "What project ?"
Is it a Ferrari fender, airplane wing or a rustic tool box ?
If you need a perfect cut without screwing anything up sandwich it between two pieces of 1/4 ply and clamp the hell out of it.If it's just regular work a circular with trim blade or jigsaw with a 24-36 blade will do it. Put it somewhere to kill the vibration. The edge of a 2x or between two 2x which can double as a guide. Set a circular saw to bare minimum penetration. 1/2 tooth out.If you have a "real" jigsaw set the stroke to minimum. Enjoy the splinters.

 

[LXCam]

7075 is fairly resilient stuff and at that thickness will do just fine with the correct circular saw blade. Just make sure it's nice and flat so you have good saw control. And I like the idea of a sacrificial board, but don't feel it's completely needed.