[R-390] Cutting Aluminium Plate

[Bill Guyger]

Perry
I do a lot of metal work for my projects, and routinely cut aluminum sheet with a saber saw and finish with a file or the disc part of my sanding station (a combination disc and belt sander). You can sand aluminum but not grind it! Grinding aluminum will gum up your grind stone. I usually cut free hand just outside the desired finished line and file or sand down to the line. It just takes practice. I've been doing this since I was a teenager and I just turned 69 so I can usually cut a pretty close line. I'm lazy, I hate extra work :-). I also use a heavy saber saw, they don't jump around like $15.00 ones from the dollar store.
BTW!!!! Protect the aluminum surface on each side of the cut with a couple of layers of masking tape to keep the saw's base plate from scratching the metal. You can get away with only protect the side of the cut that will be the finished piece if you're going to discard the cut offs. Also if I'm going to use the sanding disc, I protect the face of the aluminum that's going to be in contact with the table of the disc sander with tape to keep from picking up scratches. Beware! sanding causes the aluminum to get hot. Wear gloves or hold on some distance back. Thin aluminum does cool down in a hurry though so it doesn't stay hot for more than a few minutes. 
The same process works for angle stock and the sanded ends are very clean you will have to deburr with a file or a deburring tool. Sanding "smears the aluminum out into the direction the sander was moving. Machinists call it breaking the edges it's also a  good idea to break the edges at square corners to keep from having sharp places that will cut you later........
Bill AD5OL

      From: Perry Sandeen via R-390 <r-390 at mailman.qth.net>
 To: "r-390 at mailman.qth.net" <r-390 at mailman.qth.net> 
 Sent: Friday, October 28, 2016 12:47 AM
 Subject: [R-390] Cutting Aluminium Plate
   
List,
Some of my A's are missing the Utah plate.
I have some very nice sheeting of about the same thickness.
I'd like to cut them on my table saw that has a new 10 inch 40 tooth carbide blade.
Good idea? Bad idea?  Pitfalls to avoid?
Regards,
Perrier
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