Is this going to cause me problems?

[Steviestevo]

Hi all,


So I'm doing a one off project that will see me have to cut some 20mm thick aluminium plate. I have a plasma cutter but that isn't powerful enough to go all the way through, and I've read you need a special disc to cut aluminium with an angle grinder safely. I really want to get this done over the weekend and can't find anywhere that does aluminium cutting discs suitable for my angle grinder in a reasonable driving distance from where I live - and to be honest, don't really want to use an angle grinder, given I'm not all that accurate with one!

The only other tool I seem to have that might be suitable is a vertical bandsaw, but its a cheap Screwfix woodworking bandsaw I bought for a restoration project before covid. I've read that aluminum can be cut in a woodworking bandsaw, but am not sure if such a thick plate would likely just end up stripping the teeth or destroying the machine. Any advice?

Thanks!

 

[Erie Fred]

Are you making straight cut's or shapes ?
a skillsaw will cut aluminum nicely.

 

[bricol]

20mm thick, I think you would struggle with a grinder disc and go through a lot of them!

I might try a metal blade in a jig saw, having made sure I had plenty of WD40 to assist in cutting and preventing the blade clogging, but I think it would still be heavy going.

 

[Steviestevo]

Are you making straight cut's or shapes ?
a skillsaw will cut aluminum nicely.

Sorry, probably should've made that a bit clearer, it's a three pointed star-like shape, so I doubt things like a circular saw would work (that was the other thing I was going to try).

 

[Erie Fred]

Your wood working bandsaw should be o.k.
If you have a blade with a pitch that keeps 3 teeth in the cut, would be best.
If coarser, go slow-er.

 

[Morrisman]

A jig saw with a razor sharp wood blade in will cut it okay, albeit slowly. Use plenty of wd40.

 

[Dozzer]

If you have a band saw, sounds like the best bet.
As @Erie Fred says, if the tooth pitch is course, go slow.

 

[fizzy]

A wood cutting bandsaw should do it nicely. Rips through aluminium at an incredible rate. WD40 as a lube.
Also a normal circular saw with a TCT wood blade should be fine as well although I haven't tried it on 20mm.

 

[dutch2u2]

I agree with the above replies
Band saw will be best, I've cut loads of 3mm aluminium not always with a fine pitched blade

 

[Kram]

You dont say how big this shape is. A hacksaw would be my choice, ideally a coarse 10 or 14 tpi blade as it'll cut far quicker than a fine blade. You can only go about 120mm deep with a hacksaw before the frame hits.

Chain drilling or drilling in from the ends may help but note that small drills will wonder.

I wouldnt have the balls to try it but, a wood router on a sturdy table and a template could work well.

 

[Agroshield]

Note that he says "cheap Screwfix bandsaw". As supplied, this will come with a cheap Screwfix blade.

With a good blade and properly set up, the machine will do it but he is not going to find such a blade in the time he has.

For me, a wax lube works better for aluminium as DW makes a messy black slurry.

...a coarse 10 or 14 tpi blade

Do you have a source for good 10tpi (hand, not machine) hacksaw blades please?

Most hacksaws allow the blade to be turned through 90 degrees giving unlimited depth but limited width, so that might be an option.

If you have a blade with a pitch that keeps 3 teeth in the cut, would be best.

His material is 20mm (3/4") thick. I am not sure Screwfix sell a machine that would take a 4tpi blade.

 

[addjunkie]

A wood cutting bandsaw should do it nicely. Rips through aluminium at an incredible rate. WD40 as a lube.
Also a normal circular saw with a TCT wood blade should be fine as well although I haven't tried it on 20mm.

Ive cut breeze block sized bits of ali with a wood cutting bandsaw. Just take your time. Standard wood blade.


The TCT option will see hot chips flying out….

 

[Melvyn Best]

A wood working coping saw used with plenty of lube would work so I think the bandsaw should as well

 

[Red'n'Black]

+1 for the woodworking bandsaw. I bought a bimetal 8TPI blade for the job. Works fine if you don't rush it.

I've never had much luck cutting any sort of thick material (more than about ½") with a jigsaw, the cut might look fine from the top side but the bottom will have wandered off by several mm.

 

[Morris]

I use a cheap (garage sale Burgess) bandsaw for aluminium. I use a woodworking blade from the local tool merchants, tpi I'm not sure of and cut lots of ally of all sorts of thickness. Despite the Burgess bandsaws getting generally put down as junk I find it really useful.

 

[Morrisman]

A wood cutting bandsaw should do it nicely. Rips through aluminium at an incredible rate. WD40 as a lube.
Also a normal circular saw with a TCT wood blade should be fine as well although I haven't tried it on 20mm.

TCT blade gives red hot swarf, normal sharp HSS wood blade gives nice cold swarf.
I’ve cut yards of 6mm checker plate with both type saws, I know which blade I prefer.

 

[Seadog]

Hi all,


So I'm doing a one off project that will see me have to cut some 20mm thick aluminium plate. I have a plasma cutter but that isn't powerful enough to go all the way through, and I've read you need a special disc to cut aluminium with an angle grinder safely. I really want to get this done over the weekend and can't find anywhere that does aluminium cutting discs suitable for my angle grinder in a reasonable driving distance from where I live - and to be honest, don't really want to use an angle grinder, given I'm not all that accurate with one!

The only other tool I seem to have that might be suitable is a vertical bandsaw, but its a cheap Screwfix woodworking bandsaw I bought for a restoration project before covid. I've read that aluminum can be cut in a woodworking bandsaw, but am not sure if such a thick plate would likely just end up stripping the teeth or destroying the machine. Any advice?

Thanks!

I've cut up a piece of ali about 50mm thick on a puny SIP bandsaw. 300W motor so I couldn't push it. Just take your time.

 

[Kram]

Do you have a source for good 10tpi (hand, not machine) hacksaw blades please?

I was mistaken, the coarse blades I use are 14tpi. However there are 12" machine blades available that would likely fit a standard hacksaw?

https://www.zoro.co.uk/shop/tools-and-machining/spare-blades/12inchx1inchx10tpi-bi-metal-hacksaw-blade/p/ZT1038322P

Another option which I have done, is when I snapped a 6tpi portable bandsaw blade, drilled holes and made several lengths into hacksaw blades.