Should I use my TS75 and CT to cut aluminum soffits?

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Kevin D.

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Nov 27, 2009
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I am contemplating using my TS75 with an aluminum blade to cut aluminum soffits on my 1080 MFT.  Somebody on another forum said that the hose is likely to get jammed with the aluminum debris/shavings going to my CT22 and not to do this.  I'd be using a paper bag in my CT22.  I do have a CT36AC also if for some reason that would be better.  Any advice/guidance on all this would be appreciated.
 
Not exactly the same but I have cut a lot of aluminum on my Kapex with no problems. I have used the CT 26 and midi.

Bill
 
I've cut quite a bit of aluminum (sheet, extrusions, angles) with TS75 and never had a problem. I used 36 mm hose and Kobalt vacuum, which is a regular shop vac. Collection is not as good as with wood, a lot of shavings escape because they are dense and don't get captured by airflow well. However, once in the hose they don't get stuck, even though my hose is suspended and goes from the saw up.
 
We've cut many 13mm thick honeycomb aluminum panels with a TS55 , 27mm hose and a CT22 with paper bag and had absolutely zero problems.  Some of them were cut with the spark arrestor attached too to make the oversight committee happy.

 
I know when I have cut aluminum panels in the past with the 27mm hose they tended to clog at the adapter. Using a 35mm hose should help tons if you really want to.

Sent from my SM-T310 using Tapatalk

 
Had no problems cutting aluminum sheets and profiles with a TS55 and CT-SYS with 27mm hose.
But I made sure to have an extinguisher at hand, just in case.

More caution needs to be executed should you want to sand aluminium, a (with some bad luck) ignited aluminium dust explosion can be very impressive. Festool has dedicated vacs for this (CT 48 B22), which are a good plan should your intention be to sand alu with the confidence of surviving it.
 
I am using Nilfisk vacuum +paper bag and I have zero problems. I am cleaning steel shavings with oil, wood dust => no problem. I think this isn't the best idea, but It works.
 
I've cut enough aluminum in the last 36 years (storefront) to fill a van with chips.  Used Makita 10-14" chopsaws with Sears and now Fein vacs with steel Oneida Dust Deputys.  Never had a problem, chips do go everywhere, I have 4" brush sweeps on either side of the blade fastened to the fence to reduce bounce back, but still cleanup is a pain.  The only time there are issues is that sometimes I get a curl instead of chips; those can clog the vac route.
 
Thanks all!  Valuable insight/info for me.

I would be using one of my larger hoses as I generally prefer anyways over the standard 27mm ones. 

Thanks on confirmation that paper bags are OK,

I don't have the  Festool 'spark arrestor' accesory, but is it needed with aluminum cutting?  I always thought it was for ferrous metal cutting and aluminum was not applicable for it.  Correct me if I'm wrong PLEASE!

Thanks again everybody!
 
Kevin D. said:
I don't have the  Festool 'spark arrestor' accesory, but is it needed with aluminum cutting?
Click to expand...
Arrestor is not needed. There are no sparks. If you are worried, start with a new bag without wood dust in it.
 
w802h said:
Why would anyone do this to a vacuum!
http://festoolownersgroup.com/festool-tools-accessories/can-you-blow-up-a-festool-dust-extractor/
Click to expand...
If the aluminum particles (fines) are larger than 500 microns, an explosion will probably not be sustained. If the material is 420 microns or finer then it has the potential for explosion.  If you are cutting, the chips are not going to be anywhere small enough to cause combustion.  If you are sanding aluminum, then don't use a vacuum cleaner unless it is wet type - and it must be grounded all the way along the system.  I have been using a vacuum for collecting aluminum from my saws for years and the only problem is the weight.  I also use a cutting lubricant, so the incidence of galling is reduced and the particles are cool enough to cause no issues in the hose or bag.
 
Xoncention said:
If the aluminum particles (fines) are larger than 500 microns, an explosion will probably not be sustained. If the material is 420 microns or finer then it has the potential for explosion.
Click to expand...

That surprises me as 420 microns is relatively large at .016" or 1/64", I would have thought the particles would need to be smaller by a factor of 10 or more. Interesting...
 
When I was a much younger man I ran a large amount of Al. siding and soffit, we always used a C saw with a reversed plywood blade, that gave us the smoothest cut. Also worked on vinyl products. Hope it helps. B
 
Brent Taylor said:
...we always used a C saw with a reversed plywood blade, that gave us the smoothest cut. Also worked on vinyl products.
Click to expand...

I still use a reversed blade on my Kapex to cut pvc tubing.
 
Hope the OP doesn't mind if I ask about the cleanup with aluminum considering it is very much possible to use the TS 75 and the Kapex.  I've used oil with drilling or tapping with aluminum, but is oil needed with cross cutting on a kapex or ts 75?  Does oil not stick to the inside of the hose or suction piping of the saw?  I'm curious.  Recently I've been cutting aluminum extrusion (8020), and have had no problems with cross cutting or any burn marks on the cut using a kapex.  Does oil not make it harder to clean up?

Jeff
 
Cheese said:
Xoncention said:
If the aluminum particles (fines) are larger than 500 microns, an explosion will probably not be sustained. If the material is 420 microns or finer then it has the potential for explosion.
Click to expand...

That surprises me as 420 microns is relatively large at .016" or 1/64", I would have thought the particles would need to be smaller by a factor of 10 or more. Interesting...
Click to expand...
The Aluminum association F1 guidelines details the safe handling of fines.  This is their data. The National Fire Protection Association Standard No. 484 Standard for Combustible Metals also has similar data.
 
CarolinaNomad said:
Hope the OP doesn't mind if I ask about the cleanup with aluminum considering it is very much possible to use the TS 75 and the Kapex.  I've used oil with drilling or tapping with aluminum, but is oil needed with cross cutting on a kapex or ts 75?  Does oil not stick to the inside of the hose or suction piping of the saw?  I'm curious.  Recently I've been cutting aluminum extrusion (8020), and have had no problems with cross cutting or any burn marks on the cut using a kapex.  Does oil not make it harder to clean up?

Jeff
Click to expand...

I'd use WD-40 or a waxy lube rather than oil. This is what Hans at TSO reccomends.
 
I've been chopping up aluminum storefront material for 36 years...I buy WD-40 by the gallon and use cheap spray bottles to apply.  I've literally cut up 55 gallon loads of chips over that time.  The newer blades do not need nearly as much lub as the old blades.  I use Amana's blue coated aluminum cutting blades now and only occasionaly lub and even better I often do not even need to file the finished edge. 
 
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