Best way to reduce the width of this Aluminium flange

  1. RonA

    RonA specialist in repairing sealed for life equipment

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    5B84D459-1308-4509-BE1E-57840F75985A.jpeg Just had these louvred bonnet sides made up for my project car & unfortunately the flange has been made up too wide. The panels mate with a stainless s/s hinge which has a similar but opposite fold & I need to pare something off the edge of this panel to make it fit.
    If it had been mild steel would just have run a slitting disc along to chop off the excess. Never used Aluminium slitting discs are they just as easy to use & do they give a clean cut?
    Ideally would have liked to straighten it out & guillotine the edge but suspect it would damage the nice clean fold.
    RonA
     
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  2. hotponyshoes Member

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    846
    Location:
    Somerset. Uk
    You can get 1mm ish thick cutting discs specially for alloy, they do cut alloy better than a steel one but due to it being alloy it still won't be a really nice cut.
    If you could put some scrap in behind the flange you will get a better finish if you cut through the flange into something else.

    A nibbler would be another option but it does not look like there is room to get the head in there

    Or a circular saw (with a metal blade if you have one but wood will work), raise the deck so you only have just enough blade sticking out and set the guide against the outside of the flange. You will still want something behind the flange to cut into though, thin wood if possible

    It might be possible to cut 90% of the way through with a disc then snap it off if you can't get something behind the cut.
    If you cut all the way through the dross is going to be facing downwards and awarkward to remove, if you just leave a snapped lip you can file it off sideways
     
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  3. Ton-up

    Ton-up Member

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    That's the most 'steel' looking bit of ally I've seen!
     
  4. gordon stephenson

    gordon stephenson Forum Supporter

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    I have used stone cutting discs quite a while ago to cut ally, and it worked very well.
     
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  5. Screwdriver

    Screwdriver Member

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    4,538
    UK London
    Nice new sharp carbide wood cutting disk. Make up a travelling guide to stop it going through the bottom piece.

    Maybe one of those oscillating tools might do it too, assuming you're more concerned with not damaging the other bit than a perfect cut. You can always flatten a wobbly cut with a file if its ally.
     
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  6. pedrobedro

    pedrobedro Man at Matalan

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    I'd use my nibbler.
     
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  7. RonA

    RonA specialist in repairing sealed for life equipment

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    Obviously, you've not seen many pieces of Aluminium, you should get out more. Would you like it weighing?
    RonA
     
  8. cianh91

    cianh91 Member

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    1mm disc bit of wood or metal behind it and plenty of wd40 take ur time and itl cut fine and nice and clean
     
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  9. brightspark

    brightspark Member

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    circular saw just with a standard carbide blade and clamp a strait edge to it. ive got one if you want to use it :)
     
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  10. RonA

    RonA specialist in repairing sealed for life equipment

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    The edge fits in the hinge & wont be seen once fitted, so providing its reasonably tidy & straight it would be ok.
     
  11. RonA

    RonA specialist in repairing sealed for life equipment

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    Thanks for the offer Brightspark I’ll keep it in mind if I get stuck
    RonA
     
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  12. Morrisman

    Morrisman Member

    Just use a normal 1mm cut off disc and clamp a length of steel strip as a guide. No dramas.
     
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  13. Morrisman

    Morrisman Member

    It looks just like steel to me too, replete with little rust marks. :dontknow:
     
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  14. grim_d

    grim_d Member

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    Looks like steel to me too, if not it's had a hard paper round, or maybe the light playing tricks?

    Pretty severe bend for aluminium too. Must be nice and soft not to crack.
     
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  15. RichardM Member

    Must say looks like steel to me too!

    1mm cutting disk with a bit of flat bar behind the cut "just in case" and a straight edge to run along.
     
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  16. Sean Another 602 fan

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    1,027
    Edinburgh
    if it was ally id run the battery rip saw up it with a bit of WD40
     
  17. Pete.

    Pete. Member

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    Kent, UK
    I'd use a cold cut saw, been using one all week at work.

    Gotta say, it might well BE ally but it sure as hell looks like hot rolled steel in the pic.
     
  18. Screwdriver

    Screwdriver Member

    Messages:
    4,538
    UK London
    It does look a bit odd. It might be a type of Duralumin, like they use for lorry bodies.
     
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  19. pressbrake1

    pressbrake1 Member

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    947
    essex england
    You can see it’s soft alloy cos of all the scratches and marks
     
  20. Richard.

    Richard. Member

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    Cambridgeshire
    It must be the way the lighting or shadow has caught it in the photo as it absolutely looks like a lump of bent steel.
    Obviously the Op is gonna know exactly what’s in front of him but if you hadn’t told us that was aluminium I doubt very much any body would of guessed it was.
     
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