cutting aluminum

[bill wisnefske]

I need to cut a 14"x 14" hole for a window in 1/8" aluminum sheet metal. whats the best tool to use?

 

[DAO]

a skillsaw with carbide tip blade, safety goggles,and don't smile while cutting it. aluminum is soft enough it won't hurt the blade sharpness.I have used my power miter cutting aluminum angle for trim on boats for years. i don't use anything special. oc.

 

[Anonymous-0]

I would drill a hole in each corner and then cut the sides with a saber (jig) saw with fine tooth blades.

 

[redtom]

I've used the Makita 4 1/2 grinder with a 1/16" slicing disc. Probably not the recommended use for the disc, but for a one time deal it works okay.

 

[JML755]

(quoted from post at 07:13:41 10/09/09) I need to cut a 14"x 14" hole for a window in 1/8" aluminum sheet metal. whats the best tool to use?

Just get a metal cutting blade for your circular saw. (usually under $10) Will be a bit noisy and make sure you wear safety goggles. Lots of little pieces of shrapnel flying around, but all in all, a pretty easy task. I've done it many times with metal siding. Draw the outline with a felt tip pen, plunge cut at the start of each side. I usually leave a small connecting piece at 2 diagonally opposite corners and connect the 2 cuts at the other corners. Helps to keep the waste piece from flopping around. Good luck.

 

[C.R.]

jig saw with a fine blade or circular saw it will be LOUD if you use a circular saw you may want to use ear plugs along with the safety glasses

 

[Mike Groom]

mjbrown has the correct way to do it,I've done it many times in my past 40 years as a model maker,drill the corners with a bit big enough to get your fine tooth blade in, run at high speed and file the corners,if you want when your done.

 

[Oldmax]

If you use a circle saw be sure to wear eye protection and face sheild, long sleves, long leather gloves. It is the fastest way.

 

[Spook]

I'd use a jig saw. I gut some roofing tin last year with a skillsaw. Never again. I will use a fine tooth blade or buy a shear of some sort.

 

[Anonymous-0]

A zip disc in an angle grinder should make easy work of it. I'm not sure if they make specific zip discs for aluminum but it would be easy to check out at a welding or industrial supply. Dave

 

[bill wisnefske]

did anyone notice this is 1/8" plate

 

[Anonymous-0]

Plasma cutter will work in the right situation. dont know what yours is..

 

[bill wisnefske]

I thought someone might suggest the dual saw. has anybody got one?