Advice needed- cutting aluminium angle technique

[venk67]

Need some help figuring how to cut 45 degree mitre cuts in alumium angle?  I do not own a kapex, but have a 10 inch Dewalt Mitre saw?  I think the blade that came with it is a " general contractor blade"

I have a TS 55 and an MFT table

and I have the trion jig saw.

Not sure what would be the easiest way to cut the alumium which is at a 90 degree angle and only 12mm wide on each side of the 90 degrees, it is 2-3 mm thick.

Appreciate any advice

V

 

[DKurzweil]

There are a couple different options you have for cutting the angle. 

Do you own an angle grinder?  This would make quick work of the angle, and you could then polish the edges smooth removing the burrs after. 

Similarly you can get a 10 inch abrasive cut off blade for your dewalt.  This shouldn't be more then about $10.  Be sure to get the thinnest blade you can.  If you go this route you need to be careful and be sure to somehow remove any sharp edges or burrs from the cut.  An advantage of using your miter saw is the ability to set the angle accurately and be sure the cut is made at the exact angle you need. 

Hope this helps,

Daniel

 

[tjbnwi]

You don't give the leg dimensions so I'll use 3/4 x3/4.

Set the aluminum on a piece of 1 by so one of he legs is pinched between the 1 by and the fence on the miter saw. At a moderate feed rate cut through the 1 by and the aluminum. The blade that came with the saw will work fine.

Friction blades do not work as well on aluminum as a toothed blade. Friction blades will make the cut, but there is to much finish work. The heat can also discolor the product.

Tom

 

[Oldwood]

If you don't have a lot to cut a triple chip carbide blade works ok. I have used a standard ATB blade for a few cuts also with no damage to the blade.
As Tom says make sure you hold it down well as it tend to chatter & wear a safety face shield. They make carbide blades for cutting aluminum & they are triple chip with a 5 degree negative rake on the teeth.

Gerry

 

[Tim Sproul]

Your Dewalt miter saw will cut that aluminum angle without difficulty.  Wear eye protection (you should always but especially when cutting aluminum with a chop saw) and take the cut slowly.

 

[venk67]

[big grin]  Thank you all,  the angle is used as body trim for the little LandRover, so the comments about heating and discoloration are very relevant.

Since I do not have an angle grinder, the Dewalt saw it is (with face shield).  Esp as I think I really only have four mitre cuts for the car itself.  the other cuts are at 90 degrees, so a hack saw is probably easiest.

The trailer will be stage 2 of the project!!

Appreciate the replies, very helpful.

 

[mattfc]

I would not use any abrasive disk on aluminium, its too soft and as well as the heat will clogg things up. Sometimes hand tools are you friend! Try using a mitre block and a hacksaw, alu is very easy to cut? Else given how small the angle is and given the size of teeth on a mitre saw, you have a bit of dnager that the blad might catch the angle, so I would be tempted to "sandwich" inbetween two biths of wood and cut through the lot, that would be the safest way

 

[AlexThePalex]

I've done this many times. Always used a mitreblock and hacksaw. Very easy. You don't need a powertool for this. Only problem with a mitreblock is that they are never 100% accurate. I always use a file to make the corner fit exactly.

 

[tbellemare]

I'd try a jigsaw w/ metal blade on some scrap. Guide it with a speed square. I think it'll work quite well. My Trion cuts aluminum like Butta'.

Tom

 

[Deansocial]

i would use a tile trim miter block and hacksaw or the chop saw it it was setup

dont use and angle grider as it will just grab the stuff and make a mess

 

[tjbnwi]

Now that I/we know the application, I would suggest that once you install the "trim" you ease the outside corner slightly. The point created by the miter joint may be sharp. Don't want your son having his first "car" accident at such a young age.

Tom

 

[mattfc]

Good point re sharp edges, if you need to wrap round a corner, I would think about cutting a "v" in one of the sides of the angle and then bending, you get a continuous smooth run then, like a mitre minus the sharp corner

 

[jmbfestool]

I used my kapex!  With a Alli cutting blade but I have cut Alli before just using the festool fine tooth blade because I was to lazy to swap the blade for one cut!

It cuts it like butter you get a dead clean smooth cut perfect for mitres!    I actually had to cut some Alli not long ago when doing oak flooring  when recessing a door matt into the floor.  I do a a frame out of the wooden floor then  the angle Alli  around the oak flooring but only showing the thickness of the all so it looks a like a thin clean line to prevent the wooden flooring getting worn on the edge when people wipe their feet

JMB

 

[venk67]

[smile]

Finally did it:

Thanks for all the advice, went ahead and used the Dewalt mitre saw, tried it on scraps first, and it worked fine, agree that a full face shield was advisable.

Had considered using the jigsaw guided by a speed square but material was just too thin, even thought about mounting the PS 300 in my CMS and using it like a mini band saw and using the mitre gauge but ended up going with speed and convenience. 

Will use a file to remove the sharpness created at the corners, thanks for that warning!

Hopefully just 2 days left on the Toylander

; windscreen to be completed tomorrow with wiring; plastic bags cover the engines, they are sealed in ziplock bags also to avoid swarf finding its way in!!

Thanks

Venk

 

[peter halle]

What a fabulous project!

Peter