Cutting aluminum

[chopthebass]

It's looking more than likely I will need to learn how to fabricate things from sheet aluminum. My question is simply - what's the best way to cut the stuff? I have never worked with the material before, but my first though would be jigsaw? Is there a better way to cut?

Thanks

[michael everson]

I guess it would depend on what tools you have at your disposal. Jig saw with a fine blade will work. Sheet metal sheer would be better. Tin snips work but can distort the edge. I have cut long straight lines with a razor knife. Just keep scoring it until you can bend it enough to crack the score.
mike

[dallas_]

A plasma cutter is nice too.

Clean, dry air from the compressor helps keep the cuts clean.

[skullandbones]

I cut the bottom out of a Moroso overflow tank to custom fit it into my engine bay. I used a friends band saw at his machine shop. He used a belt dressing for aluminum that really let the blade cut thru it like butter (1/8 inch). I just took it slow and redressed it often. I wanted a clean cut. I have used 1/16 inch cutoff wheel for inside cuts. I have some shears from HF that absolutely will cut the thin stuff with clean corners even around gentle curves and doesn't bend the edges. That's one of the more decent tools they carry. It takes some practice. I did a lot of scrape first to get used to it. It is fast and one speed. Of course, the drill press can be used for grinding and drilling. I think the ribbons of aluminum coming off is the weirdest thing ever. The metal is different in so many ways to steel. I think you just need to be a little more patient with it. The most trouble I have had is bending certain thicknesses and alloys. Some is just too brittle to do on a "break". I have also cut long straights with a sharp box cutter blade (thin stuff). I learn something every time I fool with it. I recently did an adaptor for my quick release and the drill press made the 9 holes and recesses a pretty easy job. Of course, I had to clean it up on the sander and polisher. I think it is one of the cooler things about working on these cars. Good luck,

WEK.

[Mike N]

A jig saw works fine. Use a blade that will put at least 2 teeth in contact with the metal at all times so for thin material you want a high tooth count blade. A band saw is the ideal tool :)

[David Hodgkins]

I have a small 9" Craftsman band saw. What blade type should I use to cut aluminum?

I've traditionally used a 4" cutoff wheel to cut aluminum. I used a very thin disk and tried to go slow as to not heat the metal too much but using a band saw seems like it would be a better solution - if I can figure out what type of saw blade to get.

:)

[Jester]

I used a 12inch hand shear similar to the one in this web page http://www.kmstools.com/metalworking-16000000/sheet-metal-machines-and-tools-16050000/shears-16050500/.

I sourced locally - great for mods to foot boxes etc.

I also sourced a small bench sheet metal brake to help with the bends

[chopthebass]

I like the idea of the hand shear. I do have a large bandsaw but I didn't know you can cut aluminum on it. What blade do I need?

[edwardb]

I like the idea of the hand shear. I do have a large bandsaw but I didn't know you can cut aluminum on it. What blade do I need?

Any metal cutting blade will work fine in your bandsaw for the .040 aluminum in the kit. I have a relatively small generic Craftsman bandsaw that I've used for both of my builds. I've fabbed a bunch of parts by first cutting on the bandsaw and then truing the edges on my Delta stationery disk/belt sander. For thicker aluminum, it also works OK. But take it slow and use some lube, like paraffin wax or something purpose made. I cut the one inch transmission spacer this way. Just took it slow and easy. Where necessary for closed cuts (like the holes for instruments in the dash) I use a sabre saw with a metal cutting blade. Also works fine. Steel is a different story.

[chopthebass]

Thanks Ed. I have a belt sander too, so looks like I just need a bandsaw blade.

[Arvin]

I use a dremel tool and then clean up with a flat file.

[Mike N]

If you have limited garage or shop space keep your eyes out for a used portaband saw and buy a table from Swag Off Road. I saw this in the garage journal a while back and now have a set up bolted to my workbench. Works great and can be tucked out of the way on top of a shelf or in a corner when not in use. http://www.swagoffroad.com/SWAG-Portaband-Tables-Accessories_c_35.html The saw by itself is a useful tool but the table makes it almost a daily use affair if you are fabricating or building.

[MPTech]

I use a Bosch adjustable-speed jigsaw with a fine blade. Works GREAT and I've cut A LOT of aluminum.
Replace the blades often, spray with WD-40 as you're cutting, stop and clean/cool the blade for long cuts (the WD-40 helps with both of these)and don't push too hard. If I have a long straight cut, I clamp my straight edge on and clamp the work piece to my Work-Mate, then clean up the cut with a long file and follow that up with a 300 or 600 sanding block.
I really enjoy my Aluminum mods / projects.

[Burner1]

Air nibbler works pretty good but the edge will need to be cleaned up.

[Burner1]

I have used a band saw but have mixed results. One issue I have is the speed of the bandsaw is too fast because (for wood) so I burn up blades. It's great when it cuts, not so much when it gets dull.

[carlewms]

I think the answer really depends on how much and how thick of material you intend to cut and bend.

I had the budget for it so I bought a 3-1 Combination 30 in Brake-Shear-Roller. So far it has handle just about any thing that the roadster requires. Bending 6061 T6 is a bit tricky it does not like the sharp radius created with the brake so you have to take care when bending the material not to create a cut instead of bend.

http://im1.shutterfly.com/media/47a4dd32b3127ccef5cfe6cb52fc00000030O09AaOGbRo2bA9 vPhg/cC/f%3D0/ls%3D00006064438420140313100206873.JPG/ps%3D50/r%3D0/rx%3D550/ry%3D400/

In addition to the hole cutters at the big box stores, I purchased this one which provides you some variability:

http://im1.shutterfly.com/media/47a4dd20b3127ccef5d619870b6600000030O29AaOGbRo2bA9 vPhg/cC/f%3D0/ls%3D00006064438420140301232642921.JPG/ps%3D50/r%3D2/rx%3D550/ry%3D400/

A good pair of hand shears is essential for those smaller cuts where neither the brake or the jig saw will work. Don't skimp here ... in my view you get bad cuts with cheaper version of these tools. I found that some of the best tools like these come from the aviation community since they cut a lot of aluminum panels in making their experimental airplanes. Look for a set like these:

http://www.toolup.com/images/Product/large/DWHT70278.jpg

When using a jig or saber saw I made up a guide which I offset to 1/2 the width of the base of the jig saw (The distance from the centerline of the blade to the outside edge of the base). I then clamp up the sheet metal using the guide and run the jig down the guide for very straight lines. As others have said, good blades and going slow are important.

Last but not least I have a cheap table top sander with a belt on the top and a wheel on the side which really helps fix all evils and smooth up the sharp edges. I am not sure what I would do with out it.

Another point to consider in sheet metal cutting is always drilling a small hole at each inside corner and other places where you end a cut or make a bend. You will notice this on the FFR parts. It helps spread the stresses and reducing cracking of the sheet metal later but I have found it a great way to make sure not to over cut with the jig saw or hand shear. Instead of aiming for a very tight corner you aim for the outside radius of the hole.

My 2 cents ...

Check out your local pawn shops ... you can find some nice tools at much lower costs.

Carl

[2bking]

I use a band saw with a 1/4" blade for wood with 12 tpi. It cuts through 1" stock with ease and no blade dressing. Its a Grizzly 14" band saw.

[VdubJoe]

A very good video on proper use of snips. They work very good with the proper technique .

http://www.youtube.com/watch?v=qAOQfUaRZyw

Also small belt,disc sander, cutoff wheel, and everything eles listed so far.

Joe