Replies

1. 
   jackplane | Oct 15, 2004 04:31pm | #1

   Use a carbide-tipped blade with a negative hook. It can be cut in one pass, but if the aluminum is thicker than about 1/2", two passes would be easier on you and the blade. Be sure to wear full face protection.

1. 
   ASK | Oct 15, 2004 05:05pm | #2

   jackplane,

   Always wear face protection. It is about 1/2" and L shaped. I'll probably do each leg separately.

   thanks

   ASK

2. 
   jako17 | Oct 15, 2004 05:08pm | #3

   To add to what Jack  said , apply either wax lube or even parawax to the blade before cutting

1. 
   ASK | Oct 15, 2004 07:52pm | #4

   jako

   thanks

   ASK

3. 
   Clay | Oct 16, 2004 07:58am | #5

   I would use a hollow ground plywood blade ... preferrably a cheap 7 1/4" blade (if that will fit on your saw).  Do use a cutting wax to lubricate it (WD-40 or regular paste wax will do in a pinch but regular cutting wax is better).  I have cut many large aluminum I-beams and even lots of aluminum sheet metal this way with just a portable circular saw (skillsaw).  I used to gang cut stacks of soffit metal this way, and aluminum awning pans etc.  The many small teeth of the plywood blades are much safer (cheaper too) than the large carbide teeth.  They will not last forever but you have only one cut to make.

4. 
   Steinmetz | Oct 17, 2004 01:26am | #6

   ASK, any old carbide wheel and some soap or a candle for lube. I used to cut lots of thick brass/bronze and aluminum on my Craftsman by making multiple passes. Wear an apron tied up close to your chin and use a face sheild (Those hot pieces of metal sting.) Steinmetz.  

   That one blade became my dedicated non- ferrous cutter wheel after somehow ??? one whole tooth had been knocked off  my 60 tooth forrest blade. To rebalance the blade, I removed three other whole teeth  # 15 , # 30 , and # 45.

    Still have the blade and use it for phenolic.   If you don't mind my asking , Ask, why not use a hacksaw? A Sawzall? or, a metal cutting blade in a saber saw?

   If, the shape is angular, (Ell shaped) insert or tape a short sacrifical block of wood to the area of the cut to prevent snagging of the teeth.

     Band saw?? Chopsaw?   Signed : ED REPLY

   
   

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   Edited 10/16/2004 6:30 pm ET by steinmetz

1. 
   ASK | Oct 17, 2004 04:51am | #7

   Steinmetz,

   I can probably find an old carbide wheel floating around somewhere.

   I want to use the table saw because if want the cut to be straight and square.

   I will probably do the cutting tomorrow. I let you know how it comes out.

   Thanks for the advise

   ASK

5. 
   mrles | Oct 17, 2004 07:52am | #8

   I recently bought an Accusquare fence for my garage saw and didn't have room for a 48" rail in the place I wanted to park it. I cut it on my bandsaw with an old 12t wood blade I had. I took it slow and got excellent results. I know you probably don't have a bandsaw to cut the length you need ( I sure don't ) but the ease with which it cut was a pleasant surprise.

   les 

6. 
   ASK | Oct 18, 2004 03:35pm | #9

   Ok here is the result.

   Successfully cut the 48" piece into 1-30" and 1-18' piece on the table saw. Several passes. No problem.

   But here is the problem. the Inca miter gauge which I intended to use with these pieces does not have enough height to meet the slot at the back of this extrusion.

   So, I am going to have to cut off about 1/2" along the bottom lengthwise.

   I'll let you know how it comes out.

   And again thanks for all your suggestions

   ASK