OT - Sawing Aluminum?

[tikka308]

I have to find a better way to saw cut aluminum. 1.5" wide, 0.75" thick pieces; I buy it in 144" length and cut down to 2" blanks to put into my Tormach fixture.

I currently use a miter saw with an aluminum cutting blade (Metal Devil from McMaster 6910A75). I built a stop-gauge on my miter saw, so it's not too bad. However, I hate having my hands near a 5,000 RPM, 8" blade.

I am cutting enough of these (quite a few hundred at a time) that I'd be willing to invest in a better tool for this. What do "real" shops use? My 4x6 bandsaw is too slow. Would a much bigger band saw be quicker? A cold saw? Anything more automated?

[TXFred]

Tikka,

Replace the 4x6 saw's motor with this one from Grizzly.

G2903 Motor 3/4 HP Single-Phase 1725 RPM Open 110V/220V

It's a bolt-on replacement for the original, but it runs cooler and has gobs more power.

I had to buy one of those after my original motor burned up. It has completely transformed the saw. I cut 3" x 1" stock into 3" blanks using the saw, and it gets it done quickly and without problems.

An even better option would be a bigger saw with a hydraulic downfeed and coolant system, like this one. But of course, it costs more.

G4030 6-1/2" x 9 1/2" Metal-Cutting Bandsaw

Frederic

[tikka308]

TXFred - Thanks. FWIW, I have the Jet saw (technically a 5x6, I think). I wonder if it's motor is also deficient in power.

As for the bigger band saw - my issue there is I'd still have to re-clamp on each piece, which is impractical for runs of 200+. Unless I could reliable stack the stock to cut multiple parts in each clamp....

[HorridHenry]

I hate having my hands near a 5,000 RPM, 8" blade.

Does the saw not have clamping attachments?

[tikka308]

Does the saw not have clamping attachments?

It does, but they would take took long to clamp/release for each cut. I know sounds like I am more interesting in performance than safety - and, well, that's exactly why I am trying to find a better solution. Short of an automated (hydraulic?) clamp, which would be awesome (!), clamps aren't going to help get these cut in a safe and timely manner.

[HorridHenry]

Router with an endmill and make a jig for holding the material.

Router would have to be on the slowest speed setting

[mrquacker]

Why not use toggle clamps instead? They have lots of holding power, and are quick to use.

http://www.mcmaster.com/#toggle-clamps/=gypnrc

[tikka308]

That's what I've been thinking about. Ideally, I'd use a pneumatic instead of manual (e.g. http://www.youtube.com/watch?v=mBmIbRs6-9g&feature=relmfu]Homemade DIY Chop Saw Pneumatic Clamp - WidgetWerks.com - YouTube)

Why not use toggle clamps instead? They have lots of holding power, and are quick to use.

McMaster-Carr

[tikka308]

I can't find the video or page for the life of me - but a few years back, someone DIY'd a very nice automatic clamping system that even indexed the part over (kind of like this - http://www.youtube.com/watch?v=En_Jp53I1DU]Cold Saw MC-360FA-DR.......www.worldsaw.com - YouTube) but this was a home shop setup for, I believe, a small band saw. Shot in the dark - but does anyone remember seeing this?

[Geof]

Have a look at post #35 in this thread: http://www.cnczone.com/forums/genera...luminum-2.html

[underthetire]

Tons of used automatic band saws around. Daito was a good one, doall, kaltenbach, many more. Load material and walk away for a while. Kaltenbach actually made a awesome auto feed cold saw. We used to hold .005 on that thing.

[Don Clement]

I also have used a chop saw with a 10" non ferrous carbide blade. However what works best for me in cutting aluminum is a 7x12 bandsaw with a Lennox 4-6 tpi bimetal blade shown here cutting a 6" aluminum round.


Don