Seeking advice

[CanadianScroller]

I have been trying to cut some aluminum with my scrollsaw.
The aluminum is around 1/8 thick. It is an old STOP sign.
I normally do not break blades but wear them out so they are so dull they won't cut anymore.

Not so with the aluminum. I have gone through half a dozen on the one project.
I have used some metal cutting blades but they were too thin. 0/2s
I then tried skip tooth, reverse, regular and double tooth.
The best results I got were with a number 7.
I will not mention brands because I used several and it really isn't a fair test since none of them, other than the 0/2 which I got at a garage sale were metal blades.

Does anyone have experience cutting aluminum, and what did you use?

Just for the record, I am cutting out a large gecko for a yard ornament for a friend. I want to get it done by Saturday.

[Old Dust]

There are diamond coated blades available from American Science and Surplus.

John

Old Dust

[Marcel in Longueuil]

Hi Carl,

Are you using any lubricant?

I suspect your blades are heating to the point of breakage.

And I would try a fine to med tooth, non reversing blade.

And if you're really in a bind, have you thought about modifying a hacksaw blade to fit your scrollsaw? Just a thought.

Regards,
Marcel

[Neal Moore]

Carl. I have never attempted to cut aluminum on a scroll saw but I retired from an aluminum manufacturing plant. I retired as a maintenance supervisor there but also worked as a production foreman for a while. The metal you're trying to cut is a very hard alloy, probably 5052, and is as hard as a wood pecker's lips. I would not advise cutting something that large on a scroll saw from that particular alloy. I'm not saying it can't be done but you will burn up a BUNCH of blades. If you had a softer alloy it would be a breeze with 1/8 inch stock. You're probably not doing anything wrong.....it's just really difficult to cut that alloy in as much as it's almost as hard as the blade you're using.

[uk scroller]

Hi Carl,
I have cut 1/8 aluminum with a plane old (new ) #5 blade ,i find if i smear the cutting line with a soft grease ,so that the blade runs through it on every stroke it works fine, but as Neal says there are many grades of aluminun, hope this is of some help!!!!!!!.

-----good look with the project--------- uk Scroller--------

[CanadianScroller]

Thanks so much for the info. I am sure this is the alloy since my motor gets quite hot after a short time.

I am going to get some lube and I will pick up some metal cutting blades from Canadian Tire, I know they are not the best but it is a rush project.

Live and learn

[Sparhawk]

Hey Carl.

I work in the sign industry and have fooled around with lots of aluminum. I've had to play with various road signs and some are galvanized as well. If it is galvanized it'll be even harder and really use up blades. I've cut some aluminum on my scroll saw and not had too much of a problem. Some grease or cutting wax, WD-40, any kind of lubricant will help and definitely don't use reverse blades. Another one of those cases of going really slow.

Good luck.

[bearfretworks]

....an oxyacetalene torch would get er done quickly....

[CanadianScroller]

I broke down and bought a pack of 10 mini hacksaw blades. They are 6" with pins on the ends.
I just snapped the ends of with diagnal cutters.
They are hard to turn tight cornes but I have cut out most of the project with just one blade.

[Gill]

How are you going to protect future woodwork projects against metal dust contamination?

I was going to ask what precautions you're using, but having recently had an insight into how your mind works I decided not to .

Gill