Is There Any DIY way To Neatly Cut Aluminium Sheet?

Vikki · Jul 18, 2004

I'm working on the box for my la2a and wanted to neatly cut some aluminium sheet, any ideas. Hacksaw roughs it too much and i can't get a nice straight line, i thought of keep scoring it with a straight edge and a blade of some type. Is a chopping machine the only way?
Vikki(uk) :grin:

Rob Flinn · Jul 18, 2004

I usually use a jig saw & then file a straight edge after the sawing is done.

A word of warning if you use this method:

Be sure to cover the face of the sheet with masking tape or else the underside of the jig saw will scrape/scratch the surface.

mcs · Jul 18, 2004

How thick is it? If it's 1.5mm or thinner you can cut it with a special scissor. If it's thicker I use the hacksaw + file approach.

Best regards,

Mikkel C. Simonsen

gyraf · Jul 18, 2004

I normally cut out for panel meters with a normal handheld router with a 6mm wood-cutting bit and lots of oil (in 4mm alu plate). Thet could work for cutting straight edges also, providing that you use something straight like a ruler to get the cut right.

Marik · Jul 18, 2004

For aluminum and brass straight cuts I use a table saw with wood cutting 80 teeth blades. Works well for me.

thestudio · Jul 18, 2004

YOu need a shear :grin:

Vikki · Jul 18, 2004

Thanks, i'll give some of these ideas a try this next week.
Vikki(uk) :grin:

al_p · Jul 18, 2004

Jakob,

what type of oil do you use with the router and what's your delivery method?

adrianh · Jul 19, 2004

vikki
I think Kevin C answered you but he had a seperate post.
see: http://www.groupdiy.com/index.php?topic=1143&sid=f96be1dcf6db42b6d4e13c30f7f2d259

No one tried this. Use what is called a ripfence. Real simple.
I use a 2x4 inch lumber to go totally across my piece to be cut.
Place it offset from the line you want cut about 4 cm, adjust to get
the saw blade exactly on the cut line.
It forms a stright edge to keep the jig saw stright just push the saw
to the edge of the wood.
Use large C clamps to hold the wood to the metal at the ends.
This also works great for the router method.

Yes you will need to use a file but it will be a lot strighter.

SSLtech · Jul 19, 2004

I file afterwards. Hacksaw and lotsa filing. For meter cutouts and similar, I use a rotary file in a dremel.

Keith

BYacey · Jul 19, 2004

A bandsaw works nicely with a fine tooth blade (12tpi or finer) . Afterwards straight edges and corners can be btrued up on a stationary belt sander.

Is There Any DIY way To Neatly Cut Aluminium Sheet?

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