Warbird Information Exchange

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!

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

shrike wrote: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.

Kyleb wrote: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

shrike wrote:

Kyleb wrote: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.

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

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