Cutting 1" sheets of aluminum.

[Kalvin]

Probably not the right forum, but I feel like I know you guys after reading all the threads.

My work place is having a spring clean up. Basically cleanup and dump everything. One item that has caught my eye is a worktable/jig set up that has been stored in a indoor storage area for a few years.

Now heres why I'm interested. The table top on this thing is 16' long and 2 feet wide by 1" thick aluminum. There is one joint at the 8' mark, so two sheets 8' X 2' X1".

2304 cubic inches X 0.098 lbs/ cubic inch = 225.792 lbs for each sheet.

Up until now I've been making small stuff. A hacksaw has suited me fine.

I need an idea on how I can cut this down into more workable chunks. I will most likely have to cut this down on site so that I can man handle it to bring it home. (I have no idea why I want this, but I do......I'm sure there will be a few projects I will come up with. )

I was thinking 3 cuts per sheet should give me four 50+ pound pieces.

My best guess is 6061. The lower surface still has the blue protective wrap on it, so once I get it flipped over I should be able to find out what it is.

Ok....any ideas?

[Matt McColley]

I'll bet a Super Saws All and a pack of bi-metal blades will do the job.

[cjdavis618]

Just take a skil saw with a good blade (Metal cutting blade preferably). Then cut a 1/4" depth at a time until you are through it. By using a cutting guide to rest the saw against on one side, you will be able to stay in your track each time.


You would be surprised how easy it is to cut AL plate. I have a true metal cutting circular saw that I use for steel and I can go 1/4" at a time with it also and it is just a little tougher than wood on A36 plate.


One other thing, make sure you wear some thicker clothes when you do this. The chips can get pretty warm when they hit bare skin. It is best to wear some gloves or thick clothing. ( and the obligatory eye protection )

[Kalvin]

I like the Skill saw idea.....it actually crossed my mind but I wasn't too sure if it would work.

I'll have to go looking for a good blade tomorrow.

I might even get to bring a bit of cast iron home, in the shape of a Myford lathe.
The teeth on a few of the main drive gears are sheared off, but it sure looks a lot nicer than my mini chinese set up.

Cheers,

[cjdavis618]

Glad to hear it,

Here is the metal saw I use all the time. The photo on the site sucks, but the saw is great. I use it alot to cut larger plate down. Then I use my bandsaw to go smaller with better precision.

It is noisy and sounds aweful on steel, but it works great and is doing what it is designed for.

Good luck with your projects.

[escott76]

Originally Posted by Kalvin I like the Skill saw idea.....it actually crossed my mind but I wasn't too sure if it would work. I'll have to go looking for a good blade tomorrow. I might even get to bring a bit of cast iron home, in the shape of a Myford lathe. The teeth on a few of the main drive gears are sheared off, but it sure looks a lot nicer than my mini chinese set up. Cheers,

Circular saw will work, just be extremely careful about kickback (not that you shouldn't be normally). Be very aware of where your body is in relation to the saw at all times.
I've cut 1" plate with a circular saw before, it's noisy but it works. Another option is to gang drill and then use another saw to cut the little webs. This works great for complex shapes that aren't easily cut with a circular saw, or odd shaped internal holes.

[Geof]

Skil Saw, triple chip blade marked as b eing suitable for aluminum, lubricant such as cutting fluid or use ATF, automatic transmission fluid. Don't go to fast or and make sure you have a good grip and are yourself well stabilized. You can probably do it in one cut.

[Kalvin]

Originally Posted by Geof and are yourself well stabilized.

That ones debatable.


Great ideas. Never even thought of the gang drilling.

Thanks guys.

[X2cnc]

I've cut 1" aluminum with my ordinary woodworking circular saw and a carbide blade.

You'll need long sleeves and gloves; the chips are hot enough to raise blisters. And it's very loud, too.

Give the saw a break on long cuts; circular saws are intended for intermittent duty and the motors will get hot rapidly under full load.

I used dishwashing soap in water as a coolant. Be generous with the coolant - it's best to have a helper maintain a continuous flow with a squirt bottle or something. You can let the motor cool while they refill the bottle.

[Kalvin]

Thanks for the tips guys.

Just to let you know, I didn't get to try any of them out.
My great find was scooped by someone else.

There still might be hope for my cast iron, but I have to wait.

Thank you again.

Cheers,

[Hirudin]

Originally Posted by Kalvin Thanks for the tips guys. Just to let you know, I didn't get to try any of them out. My great find was scooped by someone else. There still might be hope for my cast iron, but I have to wait. Thank you again. Cheers,

Ah man!

I weep for you...

Next time you'll know: bribery is the best policy.