Need suggestions on a saw

[fastbroshi]

Hey guys, I'm wondering what saw to buy to cut aluminum plate, maybe up to 3/8" thick for some brake caliper brackets. I'm trying to keep costs down but I'm not the type that likes buying an inferior tool to be used once or twice. I like to get my money's worth.
I was thinking buying a secondhand bandsaw and just fit it with a metal blade. Then there's so called metal saws, scroll saws, etc. Thanks in advance for any input.

 

[Jack Olsen]

Are you just making straight cuts, or do you need to shape it?

Most aluminum can be cut with an ordinary wood-cutting saw. But it depends on what kind of cuts you're making and the size of the piece that you need to feed into a saw.

 

[fastbroshi]

I would like the ability to get it fairly close to its final shape before drilling for bolt holes, plus I'd like to have a machine do it. Hacking away on something and then realizing I need a do over doesn't sound like fun.

 

[IndyGarage]

Depending on the size you need - a Milwaukee portaband is pretty handy

 

[fastbroshi]

That's probably a little too small besides being out of my price range. Let's say maybe $150 or less.

 

[Rockerbox1]

buy a jigsaw ($35 to $50) and put a metal cutting blade in it ($2)

 

[T1320T]

I have a cheapo 1 of these that I gave $50 for. I've made quite a few caliper brackets w/ it. It worked fine til I got my bigger saw which now sees most of my cutting action.

http://cgi.ebay.com/4x6-Horizontal-...=270595351438&ps=63&clkid=6293964368684555922

 

[MBeaty]

I would spring for a nice jigsaw. Personally, I don't think you can go wrong with Bosch. Any of the models, 1587, 1590, or JS470 are all high quality and are in or close to your price range. With any of these, you will find many other jobs that they are useful for.

Another option is to just use a hacksaw and files. As rudimentary as these tools seem, you would be amazed what several cuts with a hacksaw, followed by a file can achieve, especially on smaller parts and brackets.

 

[MoonRise]

CNC plasma cutter?

Your call as to where on the time-vs-money-vs-effort spectrum you want to be.

 

[gorilla]

I've been cutting aluminum shapes with a 14" import vertical bandsaw for years, it may be a little above your price range but it is the right tool for the job. The slowest wood cutting speed works well for aluminum with a good blade and some wax. I've cut some 3" plate with it with good results.

 

[83diesel]

I have cut a lot of plate aluminum with a circular saw with a carbide carpenters' blade and WD-40 with machined like cuts if you set up a temporary fence out of straight stock.

For curved shapes I use a jigsaw but it takes a lot longer than the circular saw. Circular saw will cut through the aluminum just as fast as a peice of plywood. You can pick up a circular saw or jig saw pretty cheap depending on what brand you want.

 

[Major Ramifications]

You can get a portable band saw, even a Milwaukee, for well under $100 at a pawn shop.

 

[mobetta]

X2 on a bosch jigsaw for your current needs.

then next to buy is a porta-band,

then a cold chop saw.

 

[fastbroshi]

The jigsaw is looking like the way to go the more I read. Handheld, relatively light weight. I think I may be able to get the general shape of what I need with one of these and just use a belt sander for fine tuning and dressing the edges.

 

[spongerich]

The old Delta scroll saws will do a great job cutting aluminum.

There's a "metal cutting kit" , but all you really need is a smaller drive pulley to slow it down a bit.

I got mine at auction with stand for $10. All it needed was a new blade. If you can spare the room for one, they're an excellent investment.

You can also use a variable speed router. I've never tried it, but people do it. The nice thing about going that...er....route... is that you can use a collar on the router base and follow hardboard or MDF template and get a very accurate cut that'll require minimal trimming and filing.

 

[A_Pmech]

Most any reasonably well build wood cutting band saw with a band speed of around 2,000 FPM or below will do fine with an appropriate saw band. For basic contouring of 3/8" aluminum alloy, I would use something on the order of a 10 TPI by 1/4" or 12 TPI by 3/16" Bi-Metal and adjust based on performance. Reference a band sawing radius chart to determine the width of band relative to your intended cut radii. Narrower bands will cut tighter curves.

Spray down the band and the top surface of your work with a light coat of WD-40 to reduce chip welding. Or, use Boelube in stick form.

 

[qwik]

I run a woodshop and I treat alum. like wood, table saw, joiner, planer, etc......just wear glasses

 

[qwik]

The old Delta scroll saws will do a great job cutting aluminum.

There's a "metal cutting kit" , but all you really need is a smaller drive pulley to slow it down a bit.

I got mine at auction with stand for $10. All it needed was a new blade. If you can spare the room for one, they're an excellent investment.

You can also use a variable speed router. I've never tried it, but people do it. The nice thing about going that...er....route... is that you can use a collar on the router base and follow hardboard or MDF template and get a very accurate cut that'll require minimal trimming and filing.

x2 on the flush cutting with mdf template

 

[strike a poser]

Do all of your drilling first, then go to the shapeing. It's alot easier to hold a square or retangular peice in a drill press vice than an odd shaped one. Agreed with the hand held jig saw, use a wood cutting blade though. You need rapid chip removal.

 

[fastbroshi]

Good points all, especially the last one.