Best way to cut down a 12x8x.5" plate?

[Jay C]

Hopefully the title says it all. I have a 12x8" Aluminum plate .5" thick that I want to cut in half (2 12x4 pieces). I have an CNC converted X2 ... my other tools are a skill saw, a jig saw, a router, a Dremel, a hack saw. I am thinking skill saw, but the idea seems a bit sketchy.

The plate will become a new tooling plate for my X2 which is why I posted it here. Any ideas/suggestions? I can tell you that my experience with my jigsaw and hand saw have not produced the desired finish on previous projects

Jay

[cadmonkey]

What is most critical 4" on the destined tooling plate or having two identical pieces? If you're willing to have a plate that ends up being 3.5" I'd cut it with the jig saw using some cooling fluid or WD40 to keep chips clear and get the best line you can erring on the side of the scrap side. Once you finish that then use the mill to make the edges parallel.

I've never used a skill saw (assume you truly mean handheld circular saw) to cut any metal aside from putting in a resin fibre blade and cutting ferrous metals. You'd need a really fine blade to keep from overheating/binding the saw and again use some cooling fluid - i'd avoid the wd40 as it would be easy to generate enough heat to flash the kerosene.

[Geof]

Skill saw will do it.

Get what is called a 'triple chip' carbide tooth blade that is marked as suitable for non-ferrous metals, something with 40 to 60 teeth.

Make sure the material is clamped very firmly so you are able to use two hands on the saw.

A good cutting fluid is plain ordinary transmission fluid, Dexron(?) ATF; just brush it on the cut line.

Wear ear protection and a face screen and be prepared for getting hot chips in uncomfortable places; you have to grin and bear it until your cut is finished, whatever you do don't wince and jerk the saw.

With a bit of practise and care it is possible to make cuts to with a 1/32" of an inch or better.

[Jay C]

Originally Posted by cadmonkey I've never used a skill saw (assume you truly mean handheld circular saw) to cut any metal aside from putting in a resin fibre blade and cutting ferrous metals.

FYI http://images.google.com/images?hl=e...-8&sa=N&tab=wi but it's all semantics like "coke" and "pop" I suppose

Thanks for the ideas,
Jay

[Jay C]

Originally Posted by Geof Skill saw will do it. Get what is called a 'triple chip' carbide tooth blade that is marked as suitable for non-ferrous metals, something with 40 to 60 teeth. Make sure the material is clamped very firmly so you are able to use two hands on the saw. A good cutting fluid is plain ordinary transmission fluid, Dexron(?) ATF; just brush it on the cut line. Wear ear protection and a face screen and be prepared for getting hot chips in uncomfortable places; you have to grin and bear it until your cut is finished, whatever you do don't wince and jerk the saw. With a bit of practise and care it is possible to make cuts to with a 1/32" of an inch or better.

Hmmm, I just recalled 1 more power tool I have. It's a wet tile saw Husky. It has a diamond blade now ... think I could get a 7" 'triple chip' carbide tooth blade and use it. Or would the diamond blade work too? I know these are stupid questions but like I said, the operation seems a bit dodgy to me and I want some reassurance I'm being pansy

I have cut 1/4" al sheet on a table saw and it was too bad ... a rip fence gives me a level of confidence.

Jay

[Regnar]

Take the plate to a metal shop on the way home from work and have them run it through a bandsaw. Give them 5 dollars and keep all your fingers. The place up the street has digital feed and it is always square when they are done. 5 minutes at the shop or 20 minutes of setup with hopefully a ok cut.

[LeeWay]

Don't screw up the diamond blade by cutting aluminum. HF has some 7 1/4" blades designed for plastics and aluminum. About $4 each. Nice hardened steel too. The teeth are the full width of the platten, so there is no set to the teeth. They are ground toward the outside, so the center is thicker.
Nice little blades. Just go slow. You can use WD40 or just rub a bunch of candle wax on the cut line. I have cut lots of aluminum on my table saw without special blades.

[Jay C]

Originally Posted by Regnar Take the plate to a metal shop on the way home from work and have them run it through a bandsaw. Give them 5 dollars and keep all your fingers. The place up the street has digital feed and it is always square when they are done. 5 minutes at the shop or 20 minutes of setup with hopefully a ok cut.

Well, I live in the burbs so not too many metal shops out this way

[Jay C]

Originally Posted by LeeWay Don't screw up the diamond blade by cutting aluminum. HF has some 7 1/4" blades designed for plastics and aluminum. About $4 each. Nice hardened steel too. The teeth are the full width of the platten, so there is no set to the teeth. They are ground toward the outside, so the center is thicker. Nice little blades. Just go slow. You can use WD40 or just rub a bunch of candle wax on the cut line. I have cut lots of aluminum on my table saw without special blades.

I bought a 60T Carbide blade at Lowes but I decided to call a buddy I know with a large bandsaw. Low and behold he has a metal blade too, so that's my course of action ... thanks for all the input guys. This blade is going back to Lowes.

Jay