Suggestion for Sheet Metal Tools

[djcrunkmix]

Hi guys,

I am building an Aluminum frame for my Quadcopter. I need to cut anywhere between 12 gauge to very thin Aluminum sheet metal. I got some Claus aviation snips and they sucked, so I returned them. They left serrations on the edges of the sheet metal. Overall, the edge wasn't cleanly cut.

I also have a Proxxon rotary tool which is awesome but I don't have a straight guide to cut against so the edges, again, are uneven. How the heck do you cut sheet metal? I tried nibbling the damn thing with some cheapo nibbler from Frys and it required a lot of effort for 14 gauge soft Aluminum. Plus, I would have to nibble all day long until the cows come home.

I am not going to be working on large sheets so I am looking for suggestions on sheet metal benders, cutting dies, etc. Budget isn't an issue.

I've attached some pics to show you my ****-job.

 

[Stephenw]

Use a vertical bandsaw. Aluminum can be straight cut on a tablesaw too.

 

[jayrush13]

If its just aluminum you are working with you can just use wood working tools if you want to cut sheetmetal straight a shear is the way to go but cost $$$$ unless you happen on one used

 

[djcrunkmix]

Well, I live in an apartment (Recent graduate, CAN'T wait to save up some money to buy a house...*drools*) and space is a constrain. :-(

So, I really cannot bring in a massive sheet metal shear or a table saw. What about a jig-saw? I have a couple of C-clamps to clamp the sheet on my desk.

Here is my desk:

 

[jayrush13]

I would go with power shears or a skill saw and set it up on a patio or deck if you have one

 

[Stephenw]

A jigsaw would work. You can get one with an edge guide that fits in the base for better straight cuts. You could also use a small benchtop bandsaw in an apartment.

 

[dankicksass]

First things first, get better lighting in there. You should have a straight edge if nothing else than for layouts, and you should be able to cut a straight line with snips. Just practice a little, try it out on some cardboard like a cereal box until you get the hang of it. Metal shears aren't really that expensive as tools go, and I'm fairly sure you can rent one at Home Depot, but you don't really need one. If you're not happy with the edge left from the snips you have, like if they're leaving serration marks, just clean it up with a sanding block.

 

[tyyost]

I am going to suggest malco turboshears that attach to a cordless drill.

They rock and allow you double duty for a tool you already have.

 

[Stephenw]

12 gauge is a little on the thick side for shears. That is why I recommended a saw.

Shears would work great on the thinner stuff.

 

[knobby]

One solution would be to "farm the project out" I bet you can trade your electronic skills for a fellow hobbyists metal fab skills

 

[tinbender 66]

"12 gauge" aluminum is about .100 (.109 according to a metal gauge but they don't make that) so the only way you're gonna get a good cut is with a shear (sheetmetal shop type) or with a saw. Stephenw's idea of a jigsaw would work. Not too noisy if you clamp the alum. down. Ya gotta have a straight edge!? What the hell is a Quadcopter?

 

[Elroy]

A rough cut could always be cleaned up with a file.

 

[jesko10]

You can do this perfectly with shears.

There are shears for straight cuts and some for round cuts.

The trick is just this: To avoid this up and down like on your photos, you should only use half the length of your shear ( I don't know how better to explain this in english). This way you get a nice and flat cutting edge.

 

[Mike Cohagen]

Sorry to dig up such an old thread, but just in case you are still looking for recommendations, I would try out the Jilson SuperSnips, or Edma NR1 Super Coup (same tool, different brands/labels). It's a neat hand nibbler that is made in France. The waste is about 1/16" wide and curls up -- when you press down all of the way it snips it off. It does not distort the metal at all, and barely leaves any scratches.

http://www.skygeek.com/jilson-j1451ss-metal-shear.html?utm_source=googlebase&utm_medium=shoppingengine&utm_content=jilson-j1451ss-metal-shear&utm_campaign=froogle

It works very well for clean, straight cuts on thinner metal (I've cut up to 16 gauge aluminium); but with any hand tool you will most likely never get a perfectly straight cut like you would with a press shear. I've never come closer to getting perfectly straight cuts with another hand tool.

Edit: I can get near-perfect cuts with my Wiss A11 shears, but I usually have to hammer out the edges which is a pain. The SuperSnips eliminate this problem.

 

[BWS]

Old thread....sent my pea brain to "old equip"....which then sent it to "old man".

Don't know where ya'll live but here we have a lovely turn of the century'S......cool time machine,spanning late 1700's through early 1900's.......Industrial area in a local smallish city.

One of my ALLTIME favorite places is a late 1800's sheet metal shop.Cool old brick building that if walls could talk.......DAMN.Anyway,this old joint is still in biz.They do sheet metal roofing along with built up tar/gravel.Throw in a nice biz of upscale copper work.

The old man that works in there must be push'n a 100.He lites up everytime I go in there.....mainly 'cause I talk to him and most importantly,LISTEN to what hes balthering about.....usually sumthin to do with dipchit engineers or ?But anyway.......


I go in there with a project....or customer pce...or whatever.He knows its just sumthin very easy to do,and will drop whatever big job he's doing to talk,shoot the chit and work on sumthin neat.Usually charging a cpl dollars....which will get offset when he gives me some scrap drop or sumthin?I pay the girls in the fr office with cash....wave to the old man and go about my merry way.


Moral of the story......ya'll are missing a wonderful opportunity if you have one of these old shops...and don't give them your "project" biz.And who know's....you might just learn sumthin.Not only about the craft....but about local history?best,BW

 

[Mike Cohagen]

Yes, old shops are always great but can be hard to come by these days. At least where I live, it seems as if a lot of newer shops do not want to deal with a few pieces of metal that need to be press sheared, and always want around $20+ which seems ridiculous to me.

 

[Milton Shaw]

What you are probably looking for is called a bench shear. Grizzly carries a good selection of them. They are the simplest for cutting straight lines in the type of material you are talking about. Not a whole lot of money but the do a fair job. look ag Grizzly.com for shears and you can see the various types.

 

[vintagefan]

I doubt the OP cares any more, but for those without the proper tool (a shear) you can use a table saw with a fine tooth blade just fine. Make sure it has set teeth, you dont want to risk jamming on this. If you're cutting thicker stuff, use water or light oil for coolant.

Also, use a push stick, and be careful. This task is only as safe as the person doing it.