Tool for cutting aluminium welds

[Tom B]

Hello,

I'm going to be doing some repairs on Aluminium scaffold towers and I was wondering what tools people would recommend for cutting welds as pictured below. Without causing damage to the surrounding Ali.

I know I can do it with a grinder and thin cut off discs, and I've also been recommended a tool called a Desoutter s144, but at £900+ I think not somehow!

Is there anything else that people would recommend, bearing in mind that I have an awful lot of these to get through?

 

[Jan]

How about an 'Alligator' reciprocating saw with a metal cutting blade?

 

[Wedg1e]

Oscillating cutter like a Bosch PMF180?

 

[ronan]

I didn't know you could cut aluminium with a grinder. Tried it once and the disc loaded with molten metal and wouldn't cut anymore.

 

[chevy2]

Tungten carbide cutters in a die grinder work well on ali, be sure to spray something like wd40 on the cutter so it works as a release agent so the cutter wont clog with the sticky ali.

 

[BrokenBiker]

I didn't know you could cut aluminium with a grinder. Tried it once and the disc loaded with molten metal and wouldn't cut anymore.

you can get specific discs for Ali

 

[ronan]

you can get specific discs for Ali

I must look them up, i've never seen or used them.

 

[chevy2]

you can get specific discs for Ali

My local engineers supplies had a pile of 9" ali discs on the counter last year on special for £2 each.
Rarely use my 9" grinder or do that volume of ali grinding so pretty useless for me.

 

[Number7]

Just got a two TCT blade contra rotating plunge saw off the shopping channel as a gift. I think the price was about £99 - Great for Ali. Has a wax stick feeder to stop clogging. Deff worth a look. It just falls through ali, and leaves a lovely finish. I daresay some wax residue may need cleaning before welding, tho'.

 

[awemawson]

Any makers name / model ?

 

[Number7]

Hi awemawson,
here's the link you need -
http://www.jmldirect.com/uk/diy/dual-saw/invt/d0bds40100000001
I was only given the basic package, so back to the 'net.
I bought some spare blades, the guide, and extra wax sticks - I thought the guide was a bit steep in the price department for what you get, but the saw itself seems to be a pretty solid piece of kit. I may have to look at different ways to introduce lube (maybe something other than wax?) or maybe coat the ali with wax before cutting? Experimentation required. I think the main limiting feature is that the maximum depth of cut is 26mm, but TBH I reckon I'll find ways round that. I also have a reciprocating saw that can reach into awkward places, so I should be OK for the places the dual saw can't get into.

 

[Jan]

I've been seriously considering one of these for a while now. The only reason I've been dithering is that I don't know just how wide the cut will be with 2 blades running through it.