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Old 11-22-2007, 10:48 AM   #1
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What is the best way to cut aluminum


Hi Everyone,

I have a band saw which was great for cutting metal... unfortunately, last light, it is a goner, find out the lubricate oil inside the container all used up leaving up the grearing all screw up... it is not fixable....

I don't want to buy another band saw because the one I had is a steal from EBay and there is no more such steal currently.

Now I need to cut Aluminum, could anyone suggest me a method... I need to cut angle, some with 45 degree, I need to cut square pipes...

The only think I can think of right now is a jig saw....

I am wondering can I use my portable Makita cordless wet tile saw and change the saw blade (somthing like 3.5") to some metal cutting blade to do the same...

Don't tell me I have to use my hand if I don't want to spend a few hundred bucks....

OK, after searching the net, someone said Aluminum can be cut by a wood router... here is the link

http://www.matronics.com/rv-list/hov...s/AlumCut.html

I do not 100% understand the description as you know my English....

well please share with me if you have any more detail description of agree using a router to cut aluminum will work..e.tc. thanks...


Last edited by KUIPORNG; 11-22-2007 at 10:59 AM.
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Old 11-22-2007, 11:58 AM   #2
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What is the best way to cut aluminum


I use my chop saw for aluminum, not that it's the right tool, but a carbide blade will cut it fine, I used to install shower doors and the chop saw was used to cut the header and track. I've watched guys installing commercial curtain windows do the same thing

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Old 11-22-2007, 12:10 PM   #3
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What is the best way to cut aluminum


Can you tell me what saw blade you use for that.... I suppose you mean those very high rpm miter saw which I happen to have one .... if they work, it is a life saver for me...

I meant how many teeth per inches etc... you means those use to cut wood right?
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Old 11-22-2007, 12:20 PM   #4
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What is the best way to cut aluminum


80 tooth carbide blade

I've also seen aluminum siding guys do this as well cutting soffit, they use the blade backwards.

Try both ways on a scrap piece and see what works best
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Old 11-22-2007, 12:28 PM   #5
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What is the best way to cut aluminum


Will do... thanks...
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Old 11-22-2007, 01:40 PM   #6
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What is the best way to cut aluminum


Your chop saw will do find. Don't turn the blade backward. As long as its carbide it will cut nicely.
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Old 11-22-2007, 02:58 PM   #7
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What is the best way to cut aluminum


While any 80 tooth carbide would probably work fine, they do make chop saw blades specifically for aluminum, and they work much better. Instead of ATB (alternate bevel, as most standard carbides made for wood are) they have TCG (triple chip grind) and have negative hook (also known as rake) which makes for smoother cuts with less grab.

Examples of this type of blade would be:

Everlast non-ferrous blades
Stehle non-ferrous - new generation
Tenryu alumi-cut series
SystiMatic Aluminator metal
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Old 11-22-2007, 08:49 PM   #8
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What is the best way to cut aluminum


Quote:
Originally Posted by KUI****G View Post
Hi Everyone,

I have a band saw which was great for cutting metal... unfortunately, last light, it is a goner, find out the lubricate oil inside the container all used up leaving up the grearing all screw up... it is not fixable....

I don't want to buy another band saw because the one I had is a steal from EBay and there is no more such steal currently.

Now I need to cut Aluminum, could anyone suggest me a method... I need to cut angle, some with 45 degree, I need to cut square pipes...

The only think I can think of right now is a jig saw....

I am wondering can I use my portable Makita cordless wet tile saw and change the saw blade (somthing like 3.5") to some metal cutting blade to do the same...

Don't tell me I have to use my hand if I don't want to spend a few hundred bucks....

OK, after searching the net, someone said Aluminum can be cut by a wood router... here is the link

http://www.matronics.com/rv-list/hov...s/AlumCut.html

I do not 100% understand the description as you know my English....

well please share with me if you have any more detail description of agree using a router to cut aluminum will work..e.tc. thanks...
Althought not accurate for the 45 degree cuts, you can use a sawzall/reciprocating saw.
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Old 11-23-2007, 12:00 PM   #9
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What is the best way to cut aluminum


I went to HD and the only aluminum cutting blade they carry is 7", can I install it in a 10" miter saw.... I don't really see why it wouldn't work... but would like to ask pro here... just in case.... if there is any negative effect in doing so...
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Old 11-23-2007, 12:40 PM   #10
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What is the best way to cut aluminum


The smaller blade diameter will probably not even reach the material when the saw bottoms out. Why not just order what fits correctly from Amazon.com?
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Old 11-23-2007, 12:47 PM   #11
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What is the best way to cut aluminum


You really should use the correct sized blade in any saw. Yes it will work... is it the blade meant for your saw and will it be as safe as a 10" blade? No.

You can certainly order the correct blade online, and as others mentioned, any 10" carbide blade would work... the teeth on ATB carbides are not designed to cut non-ferrous metals, but they will cut it. TCG blades are better designed to handle it.

So I'd say you should get a 10" 80 tooth carbide of any type rather than getting a 7" aluminum cutting one.

You can always order the correct blade online from the 100's of suppliers that handle them- amazon, toolking, rockler, etc.
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Old 11-23-2007, 01:13 PM   #12
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What is the best way to cut aluminum


I wish I am in US which can order online... here in Canada... online ordering is a piece of crap.... it's shipping expensive and doesn't make sense....

but anyway, I will refund the blade and get a 10" one....some other way...

and the other reason I want to use a aluminum blade is because I think there blade is thinner resulting less materials loss, because I am cutting a 96" into 4 pieces resulting 24" each piece, and I hope there will be minium loss in materials... I need peceision here... as you know this thing is expensive, try to keep buying extra piece minium..... if this saw thing doesn't work... I may have to use hand saw...

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Old 11-23-2007, 02:17 PM   #13
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What is the best way to cut aluminum


When you're at HD, don't just look for aluminum cutting blades. Look for 10" blades with negative rake (or hook), and something other than ATB (which looks like flat, left slant, right slant). I think fine veneer plywood blades, and plastic/laminate blades will have the same features.
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Old 11-23-2007, 05:29 PM   #14
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What is the best way to cut aluminum


You will loose about 3/8" makeing three cuts with a 1/8" kerf. If you really need 4 - 24" pices you won't get it out of an 8 footer. A hacksaw will give the least kerf. But your still loosing some metal. It is not possible cut without a kerf.
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Old 11-25-2007, 02:48 PM   #15
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What is the best way to cut aluminum


You work aluminum with the same tools as wood. A quality carbide toothed saw blade will cut it fine. Be sure the material is clamped securely and cut a little slower than wood. If the teeth tend to "clog" as will happen with some soft alloys of aluminum, lubricate the saw blade with a "wax stick" generally available at a contractor supplier. Be sure to wear good safety glasses and a long sleeve shirt. The chips are hot and stick to you.

Go to a local contractor supplier and get a full thickness carbibe blade, as oppossed to the thin kerf blades typically available at home centers.


Last edited by troubleseeker; 11-25-2007 at 02:51 PM.
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