Yet another aluminum cutting question

[PaulRSchmidt]

I’ve read a number of recommendations on cutting aluminum panels, but I haven’t seen a solution to this: I’m going to build my own drop trunk, and it looks like I need to cut a piece out of the middle-ish of the existing lower trunk floor such that I can reuse it. That seems to eliminate getting a jig saw started by drilling a hole at the corners. My immediate thought is to use a mini cutoff wheel on my Dremel along the cut line to clearance for the blade. Reasonable? Or dumb n00b idea?

[Traveller]

That works well. I typically just started with a drill hole as you mentioned, but I have done exactly what you describe if I wanted to save the cutout piece - start along the cutline with a Dremel cut off wheel, then switch to jigsaw. Works fine.

[WIS89]

Paul-

A simple hole in the corner followed by a jigsaw as we all learned in shop class will work perfectly as the previous response answered. Also, the Dremel tool will work, but I find it hard to use to make long straight cuts. If you are looking at a jigsaw alternative, I used an angle grinder with a cutoff wheel and had decent success with it. It's just a larger Dremel tool really.

I think you can use any of these methods, and probably a few more, to get the cutout that you need.

And, don't ever worry about noob questions; we all have had them, and everyone here is pretty good at being thoughtful in their responses! It's a pretty safe space filled with some really great guys who ar always happy to lend their thoughts and experience. And, they are especially good at spending your money!! :rolleyes:

Give it heck, and let us know how it turns out!

Regards,

Steve

[Jeff Kleiner]

Use the Dremel or cut off wheel in a pneumatic die grinder to make your 4 corners then just “connect the dots” with the jigsaw.

Jeff

[j.miller]

Chainsaw & Dynamite, but that's just me...da Bat

[PaulRSchmidt]

Paul-

A simple hole in the corner followed by a jigsaw as we all learned in shop class will work perfectly as the previous response answered. Also, the Dremel tool will work, but I find it hard to use to make long straight cuts. If you are looking at a jigsaw alternative, I used an angle grinder with a cutoff wheel and had decent success with it. It's just a larger Dremel tool really.

I think you can use any of these methods, and probably a few more, to get the cutout that you need.

And, don't ever worry about noob questions; we all have had them, and everyone here is pretty good at being thoughtful in their responses! It's a pretty safe space filled with some really great guys who ar always happy to lend their thoughts and experience. And, they are especially good at spending your money!! :rolleyes:

Give it heck, and let us know how it turns out!

Regards,

Steve

The issue with the corner hole is I’m trying to preserve the interior part as much as possible. I’ve got a larger cutoff wheel, but even though I’ve seen YouTubers cut perfectly straight lines with them (looking at you, Fitzee), I’ll go the jigsaw route with a straightedge after deathwheeling the corners.

But thanks for the encouragement!

I’ll post a pic here of the cutout in a day or three if it’s not too embarrassing…

[PaulRSchmidt]

Chainsaw & Dynamite, but that's just me...da Bat

I do like the way you think…

[CraigS]

A multi tool is a lot easier to control.
https://www.homedepot.com/p/DEWALT-3-Amp-Oscillating-Multi-Tool-Kit-29-Piece-DWE315K/204841480
Corded or battery powered. This makes nice straight cuts.
https://www.homedepot.com/p/Milwaukee-3-1-2-in-High-Carbon-Steel-Universal-Fit-Segmented-Wood-Cutting-Multi-Tool-Oscillating-Blade-1-Pack-49-25-1121/313769924
You can start your cut anywhere you want and no need for a pilot hole.

[Jeff33Ford]

A multi tool is a lot easier to control.
https://www.homedepot.com/p/DEWALT-3-Amp-Oscillating-Multi-Tool-Kit-29-Piece-DWE315K/204841480
Corded or battery powered. This makes nice straight cuts.
https://www.homedepot.com/p/Milwaukee-3-1-2-in-High-Carbon-Steel-Universal-Fit-Segmented-Wood-Cutting-Multi-Tool-Oscillating-Blade-1-Pack-49-25-1121/313769924
You can start your cut anywhere you want and no need for a pilot hole.

Just what I was thinking even for the starting point. I have one of these and you will use it everywhere. Sanding in deep sharp corners, cutting flush to another object, with a narrow straight cutter making perfect small square holes.

[PaulRSchmidt]

A multi tool is a lot easier to control.
https://www.homedepot.com/p/DEWALT-3-Amp-Oscillating-Multi-Tool-Kit-29-Piece-DWE315K/204841480
Corded or battery powered. This makes nice straight cuts.
https://www.homedepot.com/p/Milwaukee-3-1-2-in-High-Carbon-Steel-Universal-Fit-Segmented-Wood-Cutting-Multi-Tool-Oscillating-Blade-1-Pack-49-25-1121/313769924
You can start your cut anywhere you want and no need for a pilot hole.

Ah! I have one of those, but it never occurred to me it would work here. I think I’ll still use a jigsaw with a fence for the long runs, but this should work great in the corners.

[J R Jones]

I have pondered the oscillating tool Craig suggests but never used one. Like a jig saw, vibration may be an issue, with noise and accuracy the consequence. Clamping and/or fixturing aluminum sheet can be difficult.
Material thickness and alloy also complicates cutting. The FFR common 0.040 is relatively easy. I use that in light duty applications but usually I require structure and use 11 and 8 gauge.
Hard 6061 cuts clean, malleable 5052 can get raggedy. I start by drilling the corners and connecting them with saw or abrasive disc or both. Again the 0.040 can be cut with an air-die grinder but they have little torque. I like the high speed (13,300 RPM) electric angle grinder. I get away with 6.0 dia discs and 4.5 dia is safer. 0.045 thickness is effective and edge speed is everything, but they often can not get into the corners where the jig saw finishes the cuts.
jim

[vtullomk4]

I bought this drill attachment nibbler on Amazon. Works great. Cuts smoother than a jig saw. Practice cutting on scrap until you get a feel for cutting speed.

https://www.amazon.com/dp/B07FQ7M16H?ref_=cm_sw_r_cp_ud_dp_SJJ02QGFTJY47C21V NGT

Vince

[BEAR-AvHistory]

I bought this drill attachment nibble on Amazon. Works great. Cuts smoother than a jig saw. Practice cutting on scrap until you get a feel for cutting speed.

https://www.amazon.com/dp/B07FQ7M16H?ref_=cm_sw_r_cp_ud_dp_SJJ02QGFTJY47C21V NGT

Vince

Found a nibbler does a very good job on the FFR alloy, have a pneumatic one.

[john42]

I think every day some one links something that I suddenly think I need to buy... That nibbler looks wonderful!

[Mike.Bray]

For 0.040" aluminum I would use these hand nibblers, you'll be surprised how fast and easy they cut. I got these forever ago from Eastwood.
https://www.imagecoast.com/images/MichaelBray1/cimg0485.jpg

For more grunt I use these pneumatic ones from Snap On.
https://www.imagecoast.com/images/MichaelBray1/cimg0487.jpg

[CraigS]

An advantage of the half circle blade is that you can hold it so it just barely penetrates through the aluminum. This way the vibration is nearly parallel to the aluminum panel so there is much less of the panel bouncing as you cut. I actually got this for wood working. We had decided to put tile in the laundry room and powder rooms. The hard part was shortening the vertical trim at the door way. I used a scrap piece of tile for a gauge and sliced the trim w/ one of the half round blades like butter.

[PaulRSchmidt]

Ok, reasonable success.

I first started cutting with a 3” cutoff wheel, but that was a bit hard to control, and incredibly slow; did maybe 4” of cut before giving up. So I used the Dremel cutoff wheel to get the slot started, then the jigsaw to do the rest. I skipped rigging a fence, and that only bit me a little reaching at the end of one cut. The main drawback here is that the jigsaw base scratched the aluminum, but since it’ll be carpeted, it’s not a concern.

All in all, not great, but fairly good. Don’t know if you can make out the cut out floor in place, with the center piece lying on top of the gas tank:

165843

Next up, making cardboard templates for the sides.

[CraigS]

Very nicely done. For your side pieces, be sure to bend a 1 inch flange on as many sides as you can. They really ad to the overall strength of your finished box. Also build a hinged top.
https://live.staticflickr.com/65535/49321524961_429b147650_z.jpg (https://flic.kr/p/2i9nH32)Trunk2 (https://flic.kr/p/2i9nH32) by craig stuard (https://www.flickr.com/photos/152454123@N04/), on Flickr
https://live.staticflickr.com/65535/49321027863_687c2f0575_z.jpg (https://flic.kr/p/2i9kagn)Trunk 1 (https://flic.kr/p/2i9kagn) by craig stuard (https://www.flickr.com/photos/152454123@N04/), on Flickr
I found that even w/ stuff on top of the door, I could pick up the edge of the rear section to get small stuff in or out.

[john42]

CraigS how big is your fuel tank? In my car the racing fuel cell takes all the space. My tank is 22 gallons.

[vtullomk4]

I went with a plywood panel, covered in carpet. Press fit. Easy in, easy out.

Vince

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