cutting/grinding aluminum sheet

[indulf]

do i need a special cutoff wheel for my angle grinder in order to cut aluminum?

any resources or brand names for the type of flap wheel or grinder wheel i need for aluminum?

thanks :D :beer:

[De Ranged]

Ask in at any decent tool shop and they'll tell you whats best...

Me I don't do to much in alloy so I use what I've got :smokin:

This is what I've found works
a jigsaw with multi-purpose blade "wood/plastic/nails" its gota have resumble teeth on it small ones block up set it up with the smallest amount of lead on the blade (forward push) and use WD40 as a lube, this will help with slow down the metal melting to the blade:rolleyes: I've cut 1'' thick tool plate doing this... if going this thick don't expect to cut curves drill turning pionts and cut in straight lines
Cutting disks on the grinder use the thin 1mm ones they don't block up like the normal cutting disks
Grinding... steer clear of the expensive alloy grinding disks, Yea they are awsome for the job they just cost a lot and don't last like normal disks, I use the cheapest flapdisks and a piece of scrap steel :cool2: when the flap disk starts to "gum up" with alloy buzz it over the edge of your piece of scrap and its all good again... only really an issue when going hard on a flat surface

as for brands whatever is cheapest on ebay

Cheers Reece

[cybergeek23851]

X2. Aluminum is nice to work with and machine, but will sometimes "gum up" abrasives like Reece said.

[stock 87]

I use a metal shear, looks like a hand drill with jaws on the front, cuts like butter. Regular grinding wheels cut fine but do gum up.

[TheRamChargerMan]

get some beeswax and put it on the wheel. it will let it cut and not gum up.

just put it on while the wheel is spinning.

They do that here in the shipyard.

[Yadranco]

I used sawzall and circular saw with blade for metal.If you have more money than time, those grinding wheels can be found at your local welding supplier.

[300sniper]

i usually use a jig saw. i have made a nice oil pan flange our of 1/4" 6061-t6 using it. i have cut plenty of 1/8 al with the jig saw also. one thing to consider is it is going to scratch up the finish pretty bad if you don't protect it. i usually put masking tape on the area the tool will touch. if you get the pvc film on the aluminum this also protects it.

[PDR John]

One more thing to remember is with 1/8 in. or thinner straight cuts, you don't always have to cut all the way through. Just score it and it will brake off with no effert. Then clean up the edges with an 80 grit disk.

[Vortec_Cruiser]

I use a circular saw with carbide-tipped teeth. The more teeth, the better. Cuts aluminum like butter. Wear eye protection! :)

[300sniper]

I use a circular saw with carbide-tipped teeth. The more teeth, the better. Cuts aluminum like butter. Wear eye protection! :)


and ear protection. this is loud.

[Bruce T]

The brand "Forney" has aluminum specific cutting and grinding wheels, along with stainless and mild. They should be available at Ace, True Value, any farm store or some auto parts stores, Like auto value's or napa. They won;t load up.

[CoryHinsz]

You can also use a plasma cutter if you have one.

[sn0border88]

if you get an aluminum grinding wheel make sure to wear good eye protection, they throw grit like a mofo and it HURTS. Not like a normal abrasive wheel.

[Vortec_Cruiser]

and ear protection. this is loud.

You're absolutely correct! I forgot about the noise.

[Duallie]

I did this for 4 years in the pre-plasma days.
Skilsaw with a carbide-tipped blade is all we used. Some Pam cooking spray on the blade and plastic on the saw shoe. Small pieces got cut on a bandsaw with a fine-toothed blade.
We also used angle sanders with rubber backers and 80-120 grit, Bondo files, stainless steel toothbrushes, and angle grinders with aluminum-specific grinding wheels.
If you're gonna weld the joints, it's impossible to get the seam too clean. Acetone/file it clean/more acetone.

[JTRUCKJMC]

X3 on the circular saw for long cuts. Used to do yacht extensions on Alum. boats. Cut alot of alum. even up to 3/4" plate and bar (6061-T6) with a worm
drive circ saw. We also rigged up pneumatic polishes / grinders with 4" circ blade for smaller cuts, adjustments, trimming and fitting. :smokin: