Is There Any DIY way To Neatly Cut Aluminium Sheet?

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:

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.

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

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.

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

YOu need a shear :grin:

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

Jakob,

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

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.

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

Keith

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.