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What is the best tool to cut a 4'x8' sheet of 3mm thick 5052 aluminum into 12"x12" squares? I do not have access to a plasma or shear.

Circular saw with a metal cutting wheel?
 

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What is the best tool to cut a 4'x8' sheet of 3mm thick 5052 aluminum into 12"x12" squares? I do not have access to a plasma or shear.

Circular saw with a metal cutting wheel?
No. But a metal cutting circular saw would be my choice.
 

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Dont need a metal cutting blade just a carbide tooth blade. Clamp a piece of angle to it as a guide and you can get it to cut real close. Thats a lot of cuts though might be better off to call around and find a shop to shear it up for you.

Toddy
 

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Jigsaw? Plasma cutter?

You have lots of options. I bet you could even find a shop that would shear it for you (for a price of course).
 

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Jigsaw? Plasma cutter?

You have lots of options. I bet you could even find a shop that would shear it for you (for a price of course).
Winner!

For probably about the cost of a few metal cutting blades any shop with a shear can cut that for you in less than 5 min.

Our price would be about $20 for a 4x8 cut into 12x12 squares.

And since its only 3mm thick a saw would probably leave a nasty cut.
 

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If you consider your time being worth anything, paying someone to shear it is the way to go. The metal shop out here that is overpriced on everything only charges $3 a cut.
 

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oh, and wear ear plugs.

I've been around 3/4" plate aluminum being cut with a circular saw... like nails on a chalk board only 1 million times louder.
 

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Circular Saw or Table Saw with an everyday carbide blade.

Hit the edges with a file or a light flapdisc and your golden.


Probably take less time that it would to take it to a shop and wait to have them sheer it.
 

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Discussion Starter #14
Awesome. I have a bucket load of old carbide blades for my circ saw. I may go the shear route next time.... Actually I will buy them precut instead of in a 4x8 shett! :D
 

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oh, and wear ear plugs.

I've been around 3/4" plate aluminum being cut with a circular saw... like nails on a chalk board only 1 million times louder.
Actually 2 millions times louder!

We cut some 1/2" tooling plate at work awhile back with a standard circular saw/carbide blade , it's very effective but dangerously loud!

Wear plugs/phones and long sleeves , the alu. chips are near molten coming off the blade.
 

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Circular saw with a plain old carbide tipped wood blade....cuts like buddah!!

Yup. A metal cuting blade just gets hot. A medium tooth carbide wood blade cuts aluminum sheet very well. Just make sure to wear some glasses.
 

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If you get it sheared, you won't have waste and will get 11 more pieces than if you cut it with a saw, you will lose 1 column and 1 row, and maybe your hearing for a while.
 
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