Cutting aluminum sheet

[Bobupndown]

Any suggestions on cutting aluminium sheet, 2 - 3mm on a DIY basis? What is most effective method?

 

[Hood]

Depends whether straight or not.
9" angle grinder is ok but if 1050 or similar grade aluminium it can clog.
Circular saw with TCT blade will work.
Plasma.

 

[Fastdruid]

I use aluminium specific cutting discs in the angle grinder.

 

[Gragson]

I use one of these, quite versatile

https://www.amazon.co.uk/WORX-WX439-Worxsaw-Compact-Circular/dp/B07S49GTS7/ref=sr_1_1_sspa?crid=38KZ937ZL2LYU&keywords=worx%2Bcircular%2Bsaw&qid=1645050524&sprefix=worx%2Bc%2Caps%2C86&sr=8-1-spons&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUEyTjYyOVpYM0dGSUhPJmVuY3J5cHRlZElkPUEwMjMzNjYyMkFUNTVHRTVURk9XSyZlbmNyeXB0ZWRBZElkPUEwODkwMzI5MVNBUlVQTVFWQUM5UyZ3aWRnZXROYW1lPXNwX2F0ZiZhY3Rpb249Y2xpY2tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU&th=1

 

[zzr1200]

Plasma is the most effective....without a doubt.

 

[striker]

I use my makita plunge saw and track. A high tooth count TCT blade works best. I have also used my plasma cutter, but saw leaves straighter neater cuts.

 

[m_c]

Pretty much anything that can cut wood, will also cut aluminium.

I trimmed some 6mm plate on my little woodworking bandsaw the other week, before smoothing of on the belt sander, as I couldn't be bothered setting up the mill to take 6mm off the edge.
Depending on what I'm doing, I'll also use the plasma cutter, metal bandsaw, or a jigsaw.

 

[julianf]

If you want a good edge, cut it a bit on the large side with whatever you like, and then finish up with a router running along a clamped up guide.

I cut a lot on a varga va1 with a tungsten tipped blade also. I suspect a hand held circular saw would give you a fair finish and a straight ish line also, but skimming the last little bit with a router will always give you the best finish.

 

[Agroshield]

I cut a lot on a varga va1 with a tungsten tipped blade also...

Any tips for a secret sauce to stop it sticking to the cutting tool? Or is the blue and yellow can a good price/performance balance? Thanks.

 

[Bobupndown]

Not got plasma or router, will be grinder, jigsaw or circular saw. Thanks.

 

[addjunkie]

Wood cutting band saws work well with ali too

 

[James1979]

Jigsaws actually work quite well

Personally out of ease as I’m normally within arms length of one I just grab an angry grinder.

Use the thinnest discs you can get. 0.8 on a 4 1/2” work the best. Hold a candle above the cut so you’re cutting the material and the candle at the same time.

You can rub wax along the line but holding the candle works the best.

 

[SierraV6]

Jigsaws actually work quite well

Personally out of ease as I’m normally within arms length of one I just grab an angry grinder.

Use the thinnest discs you can get. 0.8 on a 4 1/2” work the best. Hold a candle above the cut so you’re cutting the material and the candle at the same time.

You can rub wax along the line but holding the candle works the best.

A jigsaw does indeed work quite well and is what I use if I need to cut curves, odd shapes etc.

For straight cuts I just use my sheet metal shear - clean, quiet and easy!

 

[gordon stephenson]

I have heard that some folks use a stone cutting grinder blade on ally to better results, Maybe the disc is softer and does not blind so easily,

 

[Hood]

Normal Inox ones work fine for me, the specific Alu ones fractionally better but not enough to make the extra cost worth it. Having said that the vast majority of my Aluminium is 5083 and it cuts a lot better than softer grades.

 

[selectedgrub]

Circular saw with TCT blade will work.

 

[OJCar]

Jigsaw or a Sheet Saw

(Image shamelessly stolen of the web rather than go out in the rain to get mine to take a photo of it)

 

[Fastdruid]

Any tips for a secret sauce to stop it sticking to the cutting tool? Or is the blue and yellow can a good price/performance balance? Thanks.

I use a Aluminium cutting wax, think it's Trendiwax.

 

[Fastdruid]

Normal Inox ones work fine for me, the specific Alu ones fractionally better but not enough to make the extra cost worth it. Having said that the vast majority of my Aluminium is 5083 and it cuts a lot better than softer grades.

I've found aluminium eats the normal (I'm using Bosch Inox) ones far quicker. For a quick one off small cut though it's not worth changing disc!

 

[tom2207]

depends how much of it you have to cut ,,, if its only a wee bit , an angle grinder laser disc and a bit of soap / chalk will do .
If its a lot , fnd some one local with a guillotine and take a bag of buns or an obe ,,,, [ old brown envelope]