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#1
6th April 2013, 10:34 PM
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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
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Click to see my build photos on Flikr http://www.flickr.com/photos/67112582@N03/ Saturn MX5 Based Chassis, Limited Slip Diff & 2.4 Quick Rack. Build cost.... seems to be spending more on tools than car bits at the moment! (they will be handy in the future though). Car iva'd and passed 15/08/2014. Finished weight 572kg. 
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#2
7th April 2013, 12:24 AM
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I have read somewhere that you can cut with a jigsaw with the correct blade (that’s what I am gonna try anyway)
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My build diary is at http://thailoz.wordpress.com/
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#3
7th April 2013, 07:23 AM
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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
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You only get a woosh with a dump valve Build Thread Man Cave Mantiques Cecil Street Auto Repairs Garage Carlisle Build Cost £4181.65 - Last - Wheel Cylinders
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#4
7th April 2013, 09:09 AM
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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
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When The Results Disagree With The Theory: Believe The Results And Invent A New Theory If I had two brains I,d still be a halfwit The cave http://s1116.photobucket.com/user/my...deshow/mancave The build http://www.haynes.co.uk/forums/showthread.php?t=12669 Last edited by robo : 7th April 2013 at 09:14 AM.
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#5
8th April 2013, 11:41 AM
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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.
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Albert Haynes Roadster FAQ | Haynes Builder Locations Gallery, build thread in Lithuanian / via Google Translate.
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#6
8th April 2013, 07:16 PM
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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. 
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Any intelligent fool can make things bigger and more complex... It takes a touch of genius - and a lot of courage to move in the opposite direction. Albert Einstein http://s1199.photobucket.com/albums/aa472/JohnoSS1/ Johno
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#7
8th April 2013, 09:23 PM
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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
 There are special wheels made just for ali. http://www.abtec4abrasives.com/cutti...nium-609-p.asphttp://www.finishing.com/317/17.shtml Bob
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When The Results Disagree With The Theory: Believe The Results And Invent A New Theory If I had two brains I,d still be a halfwit The cave http://s1116.photobucket.com/user/my...deshow/mancave The build http://www.haynes.co.uk/forums/showthread.php?t=12669
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#8
9th April 2013, 04:16 PM
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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.
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Website http://www.talonmotorfabrication.co.uk/ Direct email phil@talonmotorfabrication.co.uk talonmotorfabrication@gmail.com Mobile office hours 07514098334
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