cutting aluminum

[toddjg]

which hand saw is better for cutting aluminum hack or coping which type of blades should be used.

 

[Burl]

Hack saw, fine tooth blade.

 

[<>Severed<>]

I use a hacksaw with a course blade the fine ones plug up easily but try both and see what you like if it is a big sheet and thin you can use a circular saw to cut it but it makes a ton of noise and throws shavings everywhere so be careful

 

[bomber]

if it's fairly thin, or dead soft, a woodworking band saw will slice right through it (with a metal working blade, natch)

 

[OldCarGuy]

If it's 16 gauge or thinner, with a straight edge, I'll simply score one side using a razor knife. Then bend it back and forth several times until it snaps. If it's up to 1/4” thick, I'll cut it by installing a plywood blade backwards in a circular, table, or radial arm saw. Again the chips are hot. Use good eye protection and long sleeves and gloves.

A band saw with a metal cutting blade works well also. Using water with soluble coolant is a plus.

With a hacksaw a medium pitch blade works best. Never tried a coping saw.

 

[Firetrucks]

Iif it is a big sheet and thin you can use a circular saw to cut it but it makes a ton of noise and throws shavings everywhere so be careful

I cut several pieces of aluminum treadplate last month with a circular saw. Extremely easy to cut and keep straight. You want to think about doing the cutting outside somewhere, the chips will be all over the area where you cut. I tried a hacksaw with a coarse blade and was not impressed, that's when I tried the circular saw method.

 

[rsanter]

number of teeth depend on the thickness of the material.
use wax or oil on the blade to keep the teeth from clogging up

depending on the lenth of cut I would use a hack saw or cut saw (sawsall)

bob

 

[ron in sc]

I had a piece of aluminum I used for a workbench top and took it to metal shop where they used a brake to cut it. I consider using a circular saw but I don't have one that operates at a slow speed and I did not want to ruin mine.

 

[1320stang]

buy an old circular saw at a pawn shop for $5.

 

[Brad54]

How thick is the material you're cutting? That's really the key question.
Remember that aluminum is softer than steel--I cut several pieces of 1/4-inch aluminum angle with a Craftsman miter hand saw.

Metal cutting band saws are much slower than wood cutting band saws. I'm not saying it can't be done, but it's not the best way.

I know one shop that used very course blades in their band saw for aluminum (few teeth per inch). You could almost hear the individual teeth hitting. Cut through 1/8-inch plate like butter, and left big chips, not small shavings.

-Brad

 

[RobertG]

Just use a plasma cutter.

 

[that dan]

either use circular saw or old table with carbide blade, wd40 for lube. works great.

 

[bomber]

using a wood bandsaw is absolutely not the right way, Brad, you're right!

But when needs must, and ya don't want to pony up for the "right" tool -- I've been using metal cutting blades on my 99 cash dollar american sears three wheel bandsaw to chew aluminum for almost 15 years, though, and it gets the job done.

Good call on the course blade, too! Messy, and potentially dangerous --