Which tool for cutting Aluminum?

[SK-Mike]

Got a small project to finish on my aluminum Bass Boat. I will be making some trim cuts in the aluminum Decking on the front deck, the decking looks to be about 1/8" thickness, and seems to be fairly sturdy.

I need to make Two 5" cuts, One 2" cut, and possibly another 10" cut, they will all be straight line cuts and 3 of which will connect with each other.

Installing a Recessed Trolling motor foot pedal tray on the front casting deck. Also the front deck is covered with carpet, so the cutting tool will be cutting through aluminum covered with carpet.

I have 2 tools on hand.

1. Dremel 4000 with 1 1/2" metal cutting discs.

OR

2. Dewalt 20v cordless Oscillating tool with metal cutting blades, the good ones $20 each.

I want the cuts to be precise, with minimal burring/splintering/burning.


My concern with the Dremel is with heat build up and causing the Alum. to have burned looking spots, but I feel I would have a lot of precision control with this tool.

My concern with oscillating tool, is my lack of experience with this tool, and not knowing how it cuts metal. Will is leave jagged rough edges? Is it hard to control?

Any tips or pointers are very welcome, Thanks.

 

[tarbellb]

CUT THE CARPET FIRST. You dont want it to bind up the tool.

4.5" grinder with several cutting disc. You'll like clog them quickly but you dont have that much cutting.

Fast, cheap, and you can clean up the edges with a hand file or flap disc.

 

[SK-Mike]

Ok, I was wondering if I should cut the carpet first with a razor blade, remove it out of the way, then proceed with the aluminum cuts.

 

[454ragtop]

Do you have access to a jig saw or even a skil saw? Probably easier to gat a nice straight cut with one of those.
HTH, Jim

 

[zkling]

Without seeing it, a jigsaw would be my choice.

 

[sailah]

Do you have access to a jig saw or even a skil saw? Probably easier to gat a nice straight cut with one of those.
HTH, Jim

That's what I would use and I cut a lot of aluminum. You can plunge cut with a jigsaw and then come right up to the line. I'll bring the blade cutting up to the line then hold a straightedge against the jigsaw fence to hold it straight. Honestly with such a short cut I wouldn't even bother with the fence.

I usually would scribe the line but a sharpie would make an easy line to follow.

Spray the cut line down with wd40 and it'll cut the aluminum so much nicer and almost eliminate any heat or galling of the aluminum to the blade. Makes blades last 5 times longer.

 

[2oolhound]

The oscillating tool will likely grab and bind and even slightly bend the aluminum.
I'm with the jig saw camp. The dremel might be helpful in the corners if you need exact square corners.

 

[dnschmidt]

When cutting aluminum it is imperative to use a wax based lubricant on the blade such as those made by Relton and Beolube.

 

[Ign]

Best case, abrasives (except for sanding belts) **** in Al. Worst case, they explode. Sait will offer grinder wheels for Al, but not likely in your 1.5" whirllymagig.

Another vote for jigsaw. Get a cordless for your platform or grab the $15 corded homeowner special at Walmart or HD, whatever.

 

[Ainsley]

I've cut some pretty heavy aluminum with a jigsaw. Bosch makes blades specifically for this use. Go slow and keep an eye on the teeth. The aluminum has a tendency to gall and clog the teeth. Best thing to clean up the cut is a flap disk (also heard it called an abrasive mop disk) in a grinder.
Keep your hands away from the base of the jigsaw if you are trying to guide the cut, if the blade binds it will raise the jigsaw base offv the surface then smash your finger, HARD. Ask me how I know lol.

 

[Kirbot]

Basically anything that can cut wood, can cut aluminum.

Circular saw, jigsaw, table saw, chop saw..... whatever fits best.

 

[ducksface]

Since we're recommending tools he doesn't have I vote for a knee mill.
Try the multitool. If it doesn't work to your liking use the Dremel.
Either will do fine. No need to buy a tool you don't have. A jigsaw will jack with you just as bad or worse than the two you have.

 

[Thumper68]

I would go with the jigsaw and clean up with a file.

 

[Tinner]

When cutting aluminum it is imperative to use a wax based lubricant on the blade such as those made by Relton and Beolube.

Can't emphasize this enough. Cuts like butter with some lube.

 

[Outlawmws]

Pocket knife with a saw blade

 

[Fugio]

I use the old angle grinder on most all aluminum. Cuts like butter, and straight as an arrow.

 

[Ign]

I was wrong when I said $15. $24 gets you a basic B&D jigsaw
http://www.amazon.com/dp/B001CL4ZHK/?tag=atomicindus08-20

that will do the job just fine.

It's one thing to recommend exotic tools, another to recommend something inexpensive like this which is proven to complete the task and I can't believe the OP won't have a use for it later.

Try what you have (why not) but keep this as Plan B. I'd imagine WalMart sells the same jigsaw for about the same price.

 

[454ragtop]

Indeed, might be able to borrow one also, plus there's always CL. OP seemed to stress a nice finished cut, which I have my doubts he'd get with what he has on hand.

 

[ducksface]

I have to ask:
How is an oscillator NOT a jigsaw?
Is it the foot on the jig saw that makes it more useful in this instance?

Variable speed jigsaw, variable speed oscillator ... The difference is stroke length and a foot.

 

[thebeekeeper1]

Without seeing it, a jigsaw would be my choice.

I've done that a great deal--just be sure to get a 14 tpi bi-metal blade. A finer one will plug up and a coarser one is too "jumpy."

 

[zkling]

I've done that a great deal--just be sure to get a 14 tpi bi-metal blade. A finer one will plug up and a coarser one is too "jumpy."

What works surprisingly well, is to grind a section of hacksaw blade to fit into the jigsaw.

 

[don long]

I am working on a peterbuilt aluminum sleeper, cutting it down to fit an old ford truck. I have been using my 4" die grinder with a 1/16 cut off wheel.
the trick that I discovered is bees wax keep it on the wheel and you feel like you are cutting poster board with a razor blade.

 

[zkling]

Don, are you using a standard abrasive wheel? I'll have to try that.

 

[ez-duzit]

For that small a job you could do it with a hand-held hacksaw blade. But give the oscillating tool a try, since you have one.

 

[mrborohachi]

Jigsaw



I''d love to see pics of your bass boat. I'm in the market for a small boat myself.

 

[SK-Mike]

Never really thought too seriously about the old tried and true Jigsaw, I also have a cordless model, in the same 20 v max lineup with my other cordless tools, I will stop by Lowes today and pick up some quality metal cutting blades.

I think the jigsaw would give me a lot of control over the tool and precision on the cuts, and like said can do precision work in the corners with my Dremel if needed.

Will try to upload a pic of my aluminum bass boat, not sure if I can upload from my computer, I may need to set up a photobucket acct.

 

[twertsy]

When cutting aluminum it is imperative to use a wax based lubricant on the blade such as those made by Relton and Beolube.

Absolutely this.........cuts like butter with lube. Particularly Boelube.

 

[T45]

OP consider making some test cuts in a piece of scrap alu before cutting into the boat. Something like 1/8 inch is pretty easy to get at a HW store, if not in the scrap pile (free) in some form still for very cheap. This will allow you to test your scribing and lubrication setup, get a feel for how your blade/tool work...etc, dealing with whatever debris/removal, etc. Best case is this will be a cinch, but in case its not better to have as few surprises as possible.

 

[jgorm]

Basically anything that can cut wood, can cut aluminum.

Circular saw, jigsaw, table saw, chop saw..... whatever fits best.

yeah. I use a wood chop saw to cut extruded aluminum all the time. For thin stuff using a jig saw, I use a fine tooth blade.