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  1. #1
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    How do I cut a 1/4 inch sheet of aluminum alloy?

    I've gotta cut into this sheet of aluminum. Any suggestion?

    I'm thinking metal blade on a jig saw. What do you think?

  2. #2
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    RE: How do I cut a 1/4" thick aluminum alloy sheet?

    Unless it has some alloys making it very hard, you can cut it on the table saw, with a jig saw, hand held circular saw etc with wood cutting blades.

  3. #3
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    RE: How do I cut a 1/4" thick aluminum alloy sheet?

    Whoooaaa... got the answer in an instant.

    Thanks Jerry

  4. #4

    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    I never did all the stuff that Jerry said - but I have cut plenty of aluminum. It all makes sense.

    I have drilled it, band saw cut it, milled it, turned it (lathe). It is very easy to cut.

    Metal blade for a jig saw would be good. Use a coaser metal blade tooth count vs a fine tooth count. Aluminum is a little gummy when cutting, and can clog the teeth. If the teeth do get clogged you may be able to "pick" the aluminum out of the teeth - the blade will not be dull.

    BTW - you do not want to grind it on your bench grinder - unless you have a wheel for aluminum. It WILL clog up the grinding wheel.


  5. #5
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    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    Thanks Leo.

    I'm trying to cut a piece off my old router table to make a router insert for my table saw.

  6. #6
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    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    CJR,

    I have "never" tried this...but, a ways back a couple of friends said they had turned the blade backwards on a circular saw and used it to cut through sheet metal...

    Al

  7. #7
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    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    Plasma cutter!

  8. #8

    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    After you cut it - you can deburr it with a file REAL easy.

  9. #9
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    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    Yep, conventional table saw with a conventional crosscutting (fine tooth) blade. Take it in two passes since it's fairly thick, and don't push it really hard. Be prepared for a truckload of fine tinsel.

    ...and definitely do NOT run the blade backwards. That's fine for very thin sheet, but not for anything this thick.

    The alloy doesn't even really matter if the base metal is alumin(i)um. If it's magnesium, it matters... a whole LOT... but it's probably not.

    -- Tim --

    Member of the
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  10. #10
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    RE: How do I cut a 1/4 inch sheet of aluminum alloy?

    Yeah, me thinks magnesium has a pretty low flash point. :) Could get real exciting.

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