Cutting 1/8" Aluminum? - Scroll Saw Woodworking & Crafts Message Board

Peter Wright · 08-09-2009, 05:29 PM

Good Morning,

Does anyone have experience cutting 1/8" thick soft alloy aluminum?

I have a project that calls for some pieces of it in addition to wood and find that a sabre saw creates too much vibration and bends the pieces.

Many Thanks!

Pete

wood-n-things · 08-09-2009, 05:41 PM

That's pretty thick, and I don't have any experience in cutting it.

I would think if you were to try it you would need to tilt your table and try lubricating the blade...I'm suggesting tilting the table toward you by lifting the rear of the saw so you don't get anything wet except the table and blade...

I'm probably all wet though...

Jediscroller · 08-09-2009, 07:37 PM

I would slow the speed on the saw way down and go VERY slowly. It will heat up quite a bit. I've done it in the past with a jig saw with a fine tooth blade. The material needs to be very well supported and once again you have to be aware of the heat build-up. A thin (1/4" or so) scrap wood backer attached to the aluminum with clamps or double-sided tape helps as well.

Arcy · 08-09-2009, 07:52 PM

Quote:

Originally Posted by wood-n-things

and try lubricating the blade...

What is a good way to lube the blade without causing trouble elsewhere (rust, short circuits, etc.)? Tilting the table's a good start, but is it sufficient?

I found a source for diamond blades and am thinking of trying to cut glass, not metal, so would need to keep things rather wet.

--Rob

wood-n-things · 08-09-2009, 08:45 PM

I'm going to have to defer to someone more knowledgeable than I...I would not want to steer you wrong.

minowevie · 08-10-2009, 12:07 AM

I have never cut any mettles. mmm is aluminum mettle?? no matter. I know on my saw,( Hegner) they do make a reservoir to go on it. but I don't have one. maybe you could check that out. your friend Evie

unixpro · 08-10-2009, 05:17 AM

Well, I've cut coins with the scrollsaw. They're not aluminum, but I'd think they were actually harder.

The biggest problem with metal is heat. You won't be able to handle the metal after a short time and will need to have a jig.

There are metal-cutting blades you can get (Jewlers blades from Olson), and they work very well, but you can get by with regular blades if you want. I've used 2/0, 3, and 5 in both spiral and scroll-reverse successfully. The smaller blades snapped pretty easily, but I think that's more because they're small blades than the metal cutting. Some snapped when I was tensioning them if I didn't remember not to go all the way.

I'd suggest that you just grab some scrap and give it a shot. Don't go too fast and figure out how you're going to deal with the heat.

Peter Wright · 08-10-2009, 06:21 PM

Thanks for all the replies! I will let everyone know how it works out

Pete

JimSawyer · 08-10-2009, 06:44 PM

As for lubrication... I would think an oil would be best.

Pete,
Be sure to give your saw a good cleaning after you're done cutting the aluminum. I would guess that the little chips of metal let behind would get into the wrong places on your saw and may wear on parts, and hurting your saw.
Just a thought....

KtownScroller · 08-10-2009, 06:50 PM

Quote:

Originally Posted by Arcy

What is a good way to lube the blade without causing trouble elsewhere (rust, short circuits, etc.)? Tilting the table's a good start, but is it sufficient?

I found a source for diamond blades and am thinking of trying to cut glass, not metal, so would need to keep things rather wet.

--Rob

Hi Rob - For aluminum, kerosene is the suggested lubricant. No rust either.

08-09-2009, 05:29 PM	#1
Peter Wright Junior Member Join Date: Feb 2009 Posts: 23	Cutting 1/8" Aluminum? Good Morning, Does anyone have experience cutting 1/8" thick soft alloy aluminum? I have a project that calls for some pieces of it in addition to wood and find that a sabre saw creates too much vibration and bends the pieces. Many Thanks! Pete

08-09-2009, 05:41 PM	#2
wood-n-things Behave Yourself..I can't. Join Date: Nov 2005 Location: Right here ---silly Posts: 4,478 Blog Entries: 1	That's pretty thick, and I don't have any experience in cutting it. I would think if you were to try it you would need to tilt your table and try lubricating the blade...I'm suggesting tilting the table toward you by lifting the rear of the saw so you don't get anything wet except the table and blade... I'm probably all wet though... __________________ The Mike One of them anyway. Don't be so open-minded. Your brains will fall out!

08-09-2009, 07:37 PM	#3
Jediscroller American Crafstman Join Date: Jul 2005 Location: Galaxy far, far away Posts: 3,174 Blog Entries: 5	I would slow the speed on the saw way down and go VERY slowly. It will heat up quite a bit. I've done it in the past with a jig saw with a fine tooth blade. The material needs to be very well supported and once again you have to be aware of the heat build-up. A thin (1/4" or so) scrap wood backer attached to the aluminum with clamps or double-sided tape helps as well. __________________ Kevin Scrollsaw Patterns Online Making holes in wood with an EX-30, Craftsman 16" VS, Dremel 1680 and 1671

08-09-2009, 08:45 PM	#5
wood-n-things Behave Yourself..I can't. Join Date: Nov 2005 Location: Right here ---silly Posts: 4,478 Blog Entries: 1	I'm going to have to defer to someone more knowledgeable than I...I would not want to steer you wrong. __________________ The Mike One of them anyway. Don't be so open-minded. Your brains will fall out!

08-10-2009, 06:44 PM	#9
JimSawyer Laying into Inlay Join Date: Feb 2007 Location: Lincoln, RI Posts: 1,075	As for lubrication... I would think an oil would be best. Pete, Be sure to give your saw a good cleaning after you're done cutting the aluminum. I would guess that the little chips of metal let behind would get into the wrong places on your saw and may wear on parts, and hurting your saw. Just a thought.... __________________ Jim The limits of the imagination are imaginary. No task is too tedious for Art. Rock and Scroll My Website Featherwood Woodcrafts

08-10-2009, 12:07 AM	#6
minowevie Senior Member Join Date: Nov 2005 Location: california Posts: 6,398	I have never cut any mettles. mmm is aluminum mettle?? no matter. I know on my saw,( Hegner) they do make a reservoir to go on it. but I don't have one. maybe you could check that out. your friend Evie

08-10-2009, 05:17 AM	#7
unixpro I need more weekend Join Date: Dec 2006 Location: Greater Seattle Area Posts: 615	Well, I've cut coins with the scrollsaw. They're not aluminum, but I'd think they were actually harder. The biggest problem with metal is heat. You won't be able to handle the metal after a short time and will need to have a jig. There are metal-cutting blades you can get (Jewlers blades from Olson), and they work very well, but you can get by with regular blades if you want. I've used 2/0, 3, and 5 in both spiral and scroll-reverse successfully. The smaller blades snapped pretty easily, but I think that's more because they're small blades than the metal cutting. Some snapped when I was tensioning them if I didn't remember not to go all the way. I'd suggest that you just grab some scrap and give it a shot. Don't go too fast and figure out how you're going to deal with the heat.

08-10-2009, 06:21 PM	#8
Peter Wright Junior Member Join Date: Feb 2009 Posts: 23	Thanks for all the replies! I will let everyone know how it works out Pete

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