Cutting a huge sheet of aluminum

So we have a rather large sheet of aluminum. 96" by 60.75". Was going to be a sign at the first Checkpoint but turned out to be too big for code so it's just been moving around. We're going to cut in in three pieces, 60.75 X 37 X 2 and 60.75 X 22 to use as the tops of some tables. It's 3/8" thick. Any good ideas?
We were thinking clamp two pieces of L bar to use as a guide and then cut with a jig saw or sawzall. Would like to minimize the amount of post cutting edge cleanup too. Or maybe just a skil saw and a wood cutting blade?

The trick is a blade with negative rake on the teeth. I've seen people use regular old skill saws and table saws with these blades cutting 1/2 in. aluminum. They leave a very clean edge. Clamp down a guide like you said.

C'mon, you've seen the commercials! Use a 'twin saw' with counter-rotating blades. It'll cut anything.

I'd cut it with my plasma cutter, but only because I already have one. Then clean up the edge with a straightedge and a carbide cutter on a wood router.

Do you have a jig saw? You can get metal blades for them, and with the guide, it will be super easy to cut. Especially if you have some kind of waxy lube for the blade.

The sawzall would be my next choice, but more unwieldy.

I've never cut metal with a skill saw or table saw.

Quote
Dazed_Driver
Do you have a jig saw? You can get metal blades for them, and with the guide, it will be super easy to cut. Especially if you have some kind of waxy lube for the blade.

The sawzall would be my next choice, but more unwieldy.

I've never cut metal with a skill saw or table saw.

You should do more metalworking. A good blade like I described will leave an edge close to what you get when you use a milling machine. If you want a straightish line, don't use a jig or saws all.

Quote
Dazed_Driver
Do you have a jig saw? You can get metal blades for them, and with the guide, it will be super easy to cut. Especially if you have some kind of waxy lube for the blade.

The sawzall would be my next choice, but more unwieldy.

I've never cut metal with a skill saw or table saw.

For aluminum, woodworking tools work great. In fact you want a very course blade, not a fine blade like you'd use on steel. Those just clog up and get hot, then they smear the aluminum and work-harden it. I use LPS 'gold' tapping fluid when cutting heavy aluminum. Works much better than wax or WD-40, blades last about 10 times longer than using no lube at all.

I use a vertical bandsaw to cut aluminum head castings in half...cuts easier than maple does. Very course blade, about 4 TPI!



Edited 1 time(s). Last edit at 11/16/2011 06:05PM by Ascona73.

Skill saw with a old beatup blade...(Because you dont want to ruin a new blade)
You would not beleave the thickness of aluminum sheet (almost block) wev cut with my old skillsaw.

Wood working tools works great with aluminum.
Steel is a different story.

Maybe even put the a wood blade in with the teeth backwards on a skilsaw.

Skill saws and jig saws are standard equipment for building big alloy yachts. I cut hundreds and hundreds of feet of 3/8 5031 series aluminum back in my pro yacht captain days.

Hell I even used a Bocsh Power Planer to shave down some bits... I highly recommend good ear protection for this type of work.

A scotch brush on a die grinder will make a supper nice edge finish. Again ear protection for those little whiny bastards.

One day I was cutting a few 3' by 4' holes in the deck of this maxi yacht I ran. Some people came by and asked what I was doing. I told them alloy was up to more then a $1 a pound and we had 118,000 pounds of it here, we are going to go down to the recycle yard and have our selves a hell of a party when we sell all the scrap. They made sputtering noises about; beautiful yacht, insanity, damn hippy, tragic waste, etc.

Skill saw, I cut alot of aluminum at work usually with a jig saw, but for long straight cuts skill saw rules especially with a good guide fence. lube the blade with wax too...

the guide and fence won't work with a jig saw or sawsall you gotta do that freehand...

Skill saw with regular wood blad and Alucut wax type lube... works great, fast easy, noisey!

-Martin

I did not believe until I tried it but a skil saw with blade for cutting plywood works great. Cutting in the dark under lights makes for some trippy "saw dust"

Tim- A 60 inch cut through 3/8 aluminum with a jig saw? That's a retarded idea.

Grant- Milwaukee makes a metal cutting worm drive saw. They work very well but to be honest what you are proposing would still be a long haul. I would use plasma.

---

Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

this is what you need dude:



i mean...fuck...it says thor on it....

i have used one of those on plenty of half inch plate. so loud...you need ear plugs and ear protectors at the same time...



Edited 1 time(s). Last edit at 11/16/2011 11:24PM by DirkaDirkaJack.

Quote
Rallymech
Tim- A 60 inch cut through 3/8 aluminum with a jig saw? That's a retarded idea.

Grant- Milwaukee makes a metal cutting worm drive saw. They work very well but to be honest what you are proposing would still be a long haul. I would use plasma.

I'm just throwing out other options. Although, I agree with plasma. We have a plasma cutter.

Not sure why everyone gets so butt hurt about the idea of using a jig saw to cut aluminum... they work pretty well. My comment about never cutting metal with wasn't saying its a bad idea, I was stating "I have never done it"

If he's only doing it (the project) once... *rolls eyes*