Cutting Aluminum Question (OT) Sort Of

[Norm's Coupe]

I've been thinking about making a custom trim piece for my coupe. Lost the machinist who use to do that sort of thing. He retired. However, the other day I was told I could do the job at home.

I need to cut a piece of aluminum to shape, then I can grind and polish it to finish it. I was told I could use my bench top band saw with a wood blade to cut the basic shape. Anyone ever try using a band saw with the wood blade to do this before? Don't want to screw up my band saw.

ADDED: I would be cutting a piece about 1 1/4" wide x about 3/8" thick out of a 2" to 3" aluminum bar.

[greg g]

I think they recommend the wood blade because the aluminum tends to clog the fine teeth of a hacksaw. I have used the coarse all purpose blade of my hand held scroll saw to cut aluminum in the past. I usually clamp it to a piece of waste wood, and tape the cut line to prevent chip out. You may not need this on the band saw as the direction of the saw tends to clamp the work to the saw's base plate where the reciprocating motion of the handheld tends to move it in both directions. keep some cutting oil close by go slow with light steady pressure. Try a couple cuts on scrap to hone your technique.

[james curl]

The aircraft industry cuts aluminum with band saws and scroll saws, they also cut 1" steel plate on the band saw. The harder the material the slower the blade must move. If you have a variable speed control for your band saw you can experiment on blade speed. I have cut 1" aluminum plate on a table saw to size only with a carbide blade with a large number of teeth. Very noisey, and must be fed slowely into the blade. A good saber saw with variable speed and the right blade will cut anything.

[Norm's Coupe]

The bandsaw I have is like this small one from Delta. Just a 9" hobby one that I bought for wood cutting. Only has two speeds, either off or on. I would have to feed the aluminum slower. I have several different types of saber saws. I know I could cut the aluminum with one of those. However, the part I'm trying to cut is small and would be hard to hold. Would also be too hard to clamp a small piece like this and still cut it. That's why when I heard about using the bandsaw with a wood blade it sounded good if it would work. I do have a table top 16" variable speed scroll saw. Could also put a metal blade in that. Thanks James.

Thanks for the input. Guess I'll pick up a bar and give it a try.

[Brad Lustig]

I've cut small pieces on my table saw before with no issues

[Norm's Coupe]

Brad, I have metal and concrete blades for the table saw if I could use it. I can't use a table saw to cut out what I'm doing though. I need to cut a radius in the piece. That's why it has to be done with the bandsaw, saber saw or scroll saw.

[james curl]

Norm: I have had good luck cuting intricate parts in aluminum using a round tungsten carbide grit blade in a hack saw. With the blade being round it will cut on any surface that is in contact with. These blades will also cut glass and wristpins that run in needle bearings. The cutting is slow because the cut is 1/8" wide. The thicker the material the slower the cut. Any good hardware store will have them. They also come for saber saws but have a 1/4" shank on the back side of the grit surface.

[rearview]

Norm, I had a small crummy old B&D bandsaw (before it was called B&D) that I used for cutting my little aluminum bits. I lost it when I moved last year, but it worked great just for that with a wood blade on it.

Bob