[S10 Racer]

Originally Posted by oldred

Don't try to use a cut-off disc on an angle grinder unless the disc is specifically for Aluminum, not sure there is even one out there. I tried it with my 4 1/2' grinder and one of those thin cut-off discs and the darn thing exploded on me! I guess I must be a slow learner because I tried it again and the same thing happened after cutting only a few inches, it wasn't cutting worth a darn anyway so I gave up and used a Milwaukee sawzall.


Anyone else have this happen? I meant to ask about this a couple of weeks ago when that happened but just never got around to it so when I saw this thread I thought I would mention it.

Actually I use the thin disk all the time for cutting aluminum but the disk I use are the Metabo brand. I also cut slow and if cutting steel or aluminum sheet, I first make a shallow cut on my line then go back over it until it's cut through.

[heathj1]

when cutting aluminum with a jig saw spray wd40 on blade and it wont load up then. jig saw it from the back side so you don't have to worry about scratches

[Irelands child]

I use my little Crapsman band saw up through 1/4 inch and have even done some half inch. It cuts fairly slowly and you can follow a line pretty easily - which I, at least, cannot do with my jig saw even with a good metal blade. I don't even change blades with the band saw but I do a real good clean up of chips, especially the wheel coverings. As far as holes - a good bimetal hole saw, not the cheap ones, works nicely, though you should slow the speed.

A cut off wheel will bind and break for me (aluminum will heat and expand, then grab the wheel) - so don't I wont use except on the heavier stuff.

Dave W

[Longboard]

[QUOTE=

A cut off wheel will bind and break for me (aluminum will heat and expand, then grab the wheel) - so don't I wont use except on the heavier stuff.

Dave W[/QUOTE]

I wish I had a band saw, however, anyone use a cut off wheel uisng a Dremel? I agree with the difficulty of holding the jig saw steady.

This is a dash insert and I'm only trimming the sides just a little for a better fit. Do you think going slow with the Dremel is still going to bind and mess up the aluminum?

BTW Thanks for all the help. I'm truly over my head on this one

[Irelands child]

Originally Posted by Longboard

I wish I had a band saw, however, anyone use a cut off wheel uisng a Dremel? I agree with the difficulty of holding the jig saw steady.

This is a dash insert and I'm only trimming the sides just a little for a better fit. Do you think going slow with the Dremel is still going to bind and mess up the aluminum?

BTW Thanks for all the help. I'm truly over my head on this one

Those little bitty Dremel cut off discs will disintegrate about as fast as you can install 'em. Even their little 1/2" sanding discs will disappear fast. Yeah, I know their commercials show them cutting a bolt, but it for sure it can't be anything but a soft #10 machine screw. I have a Dremel, but use it for very light work, including elongating a couple of holes today in the cowl of my AVATAR car so I could mount the hood bracket.

If you are only doing a small amount of trimming, you can use a disc or belt sander or even a disc with a $5.00 1/2" arbor adapter on a bench grinder or even a surplus motor bolted to your bench.(use your goggles, regardless)

Dave W

[pepi]

If just trimming a file is the route, alum is soft as you know take advantage of that . use some tape, green,blue whatever to mask the area front and back, protect the finish . Mark the areas to be trimmed and have at it .. it will not take long

nix on the Jig saw, it will have that panel flopping around on your bench like a fish out of water .

[evolvo]

nix on the Jig saw, it will have that panel flopping around on your bench like a fish out of water .[/QUOTE]

To avoid all that flopping find yourself a piece of that 2" thick hard foam insulation used in the building industry. 2' x 2' is a good size. You can just lay the piece of alum on the insulation and hold it lightly with your off jigsaw hand and easily cut to your scribe lines. The blade will be buried in the insulation and not even know its there. The material does not slide around either. Just make sure the blade doesn't protrude out the bottom of the foam, stack two pieces if required. This works great.