Cutting aluminium sheet
 

What is the best method for DIY sheet cutting? Is it possible to cut it neatly with a jigsaw?

I have cut all mine out with aviation snips and a hacksaw blade so far


David

I have read somewhere that you can cut with a jigsaw with the correct blade (that’s what I am gonna try anyway)

Yeah Jiggy works fine using the correct cutting blade for aluminium.

Slow speed on thin stuff, blade swing may help.

Keep the surface clear of swarf as this causes drag, and lubricate regularly with wd40 or light cutting oil.

TT

If you dont want to mark the ali cover the cut line with wide masking tape to protect the surface from the jigsaw skids. If you have some thin ply to waste plonk the ali on top of that and cut through both at the same time, that allows you to apply downward pressure to the jigsaw without deforming the ali sheet. If you are cutting long straight lines you can use a cheap hardpoint woodsaw providing you are using the wood underneath. Much better on the long cuts than a jigsaw.
Works for me:)

Bob

I found an angle grinder with 1 mm disk much easier on ally that a jigsaw. I used the jigsaw where I needed large diameter holes in 2 mm sheet, though.

You can also apply Tallow to the blade or cutting/sanding disc to help stop the clogging.
Especially when sanding ally it cuts a lot quicker without the build up of heat which then forms a burr on the ally.;)

We were always told at tech never to use ali any where near a grinding stone or wheel because it can clog the pores of the wheel ,expand and explode. This debate still runs today 35 years later but i still dont do it for that reason. A friend of mine was using a 4" grinder and for whatever reason the stone failed and took the top of his knuckle bone clean off. Kin ouch:eek: There are special wheels made just for ali. http://www.abtec4abrasives.com/cutti...nium-609-p.asp

http://www.finishing.com/317/17.shtml

Bob

At the sheet shop we don't put ali any where near grinding wheels or solid disks we use either fibre backed grit disks or flap wheels.