Need some metalworking advice

[PinecastleAAF]

I could use some advice or tips from those with sheet aluminum experience. I have some experience with sheet steel but not sheet aluminum. I have some sheet aluminum I need to cut and its 1/8th inch thick maybe slightly more. What is the best tool to use to make clean precise cuts that I could do myself with minimal tools? Will a reciprocating electric saw with the proper blade work? I tried once to cut some aluminum with a cutoff wheel. MISTAKE! One cut I need to make is a circle 9 inches in diameter.

Thanks!

[shrike]

A jigsaw with a hacksaw blade is probably your best bet.

[Kyleb]

A jigsaw with a hacksaw blade is probably your best bet.

Yep. Metal cutting jigsaw blade. Or a woodworking bandsaw. You can even use a circular saw.

The thing I've found with a jigsaw is you can only cut a little distance at a time before the blade heats up and clogs with aluminum. So you're left cutting a half inch or maybe an inch, then waiting. Boelube or some other lubricant helps with the cooling.

[shrike]

The thing I've found with a jigsaw is you can only cut a little distance at a time before the blade heats up and clogs with aluminum. So you're left cutting a half inch or maybe an inch, then waiting. Boelube or some other lubricant helps with the cooling.

Aluminum likes coarser teeth 14-18 TPI

[Kyleb]

The thing I've found with a jigsaw is you can only cut a little distance at a time before the blade heats up and clogs with aluminum. So you're left cutting a half inch or maybe an inch, then waiting. Boelube or some other lubricant helps with the cooling.

Aluminum likes coarser teeth 14-18 TPI

Agree and with thicker material that kind of tooth pitch works well. Ultimately, you want a pitch that gives you at least 1.5 teeth in the material at any given time for smoothness.

[Spitty]

Jigsaw with appropriate blade and speed.I use beeswax as lubrication.

[PinecastleAAF]

Thanks for the tips wixers that's exactly what I needed to know.