[R-390] cutting aluminum
Bill Guyger
bguyger at yahoo.com
Fri Oct 28 15:18:47 EDT 2016
And cost more than the average ham can afford unless you're one of those guys with multiple rotating towers with a stack of single band beams on each.
Bill
Sent from my iPhone
> On Oct 28, 2016, at 2:04 PM, Barry <n4buq at knology.net> wrote:
>
> As I recall, those water-jet machines are not exactly quiet either... :)
>
> Thanks,
> Barry - N4BUQ
>
> ----- Original Message -----
>> From: "Ron Bussiere via R-390" <r-390 at mailman.qth.net>
>> To: r-390 at mailman.qth.net
>> Sent: Friday, October 28, 2016 2:00:32 PM
>> Subject: [R-390] cutting aluminum
>>
>>
>> Life's too short for this kind of hassle. Just get a plasma cutter. You'll
>> never go back to any other method.
>> At IBM we had EDM and water jet machines. Plus, a Tool and Die Maker who was
>> my pal. ha ha
>>
>> ron
>> N4UE
>>
>>
>>
>> -----Original Message-----
>> From: r-390-request <r-390-request at mailman.qth.net>
>> To: r-390 <r-390 at mailman.qth.net>
>> Sent: Fri, Oct 28, 2016 2:34 pm
>> Subject: R-390 Digest, Vol 150, Issue 31
>>
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>> Today's Topics:
>>
>> 1. Re: aluminum (Frank Hughes)
>> 2. Re: Cutting aluminum sheet (Bill Guyger)
>> 3. Re: Cutting aluminum sheet (Charles Steinmetz)
>> 4. Re: Cutting Aluminum sheet for your R390 (Mike Bracey)
>>
>>
>> ----------------------------------------------------------------------
>>
>> Message: 1
>> Date: Fri, 28 Oct 2016 14:02:04 -0400
>> From: Frank Hughes <fsh396ss at gmail.com>
>> To: r-390 at mailman.qth.net
>> Subject: Re: [R-390] aluminum
>> Message-ID:
>> <CAKLfjCnreFFdY9mCyWJxwVcTmcGjZdZ7q=uv06LqQ0FQTZDSEA at mail.gmail.com>
>> Content-Type: text/plain; charset=UTF-8
>>
>> I cut up to 1/2" aluminum plate routinely with a 60 tooth, 10", carbide
>> fine crosscut. Radial arm saw. I use WD40 to keep the blade from sticking.
>> I use eye and ear protection, it is loud!
>> 73
>> Frank
>> KJ4OLL
>>
>> On Oct 28, 2016 10:56, <r-390-request at mailman.qth.net> wrote:
>>
>> Send R-390 mailing list submissions to
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>>
>> When replying, please edit your Subject line so it is more specific
>> than "Re: Contents of R-390 digest..."
>>
>>
>> Today's Topics:
>>
>> 1. Re: Cutting Aluminium Plate (Charles Steinmetz)
>> 2. Re: Cutting Aluminium Plate (Alan Victor)
>> 3. Re: Cutting Aluminium Plate (jbrannig)
>> 4. Re: Cutting Aluminum sheet for your R390 (Doug Hensley)
>> 5. Re: Cutting Aluminum sheet for your R390 (Robert Nickels)
>>
>>
>> ----------------------------------------------------------------------
>>
>> Message: 1
>> Date: Fri, 28 Oct 2016 03:49:48 -0400
>> From: Charles Steinmetz <csteinmetz at yandex.com>
>> To: r-390 at mailman.qth.net
>> Subject: Re: [R-390] Cutting Aluminium Plate
>> Message-ID: <5813031C.8040104 at yandex.com>
>> Content-Type: text/plain; charset=utf-8; format=flowed
>>
>> Perry wrote:
>>
>>> 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?
>>
>> 40 teeth is WAY, WAY too coarse to cut aluminum of any kind, and most
>> especially thin sheets. You need a 100-tooth "non-ferrous metal" blade.
>> And unless you have a very good table saw, you won't have enough power
>> to cut aluminum with a 10" blade. Most folks use 7-1/4" or 8" blades
>> for this (even if they DO have a very good saw).
>>
>> Aluminum tends to catch the saw teeth and buck, so you need very good
>> blade guards that hold the workpiece firmly down on the table, and
>> anti-kickback prevention.
>>
>> Cutting aluminum makes LOTS of noise. Neighbors-may-call-the-police
>> loud. It sounds like a thousand angry monkeys screaming.
>>
>> A metal-cutting bandsaw is a much better tool for this job.
>>
>> Best regards,
>>
>> Charles
>>
>>
>>
>>
>> ------------------------------
>>
>> Message: 2
>> Date: Fri, 28 Oct 2016 02:08:51 -0700
>> From: Alan Victor <amvictor at ncsu.edu>
>> To: Charles Steinmetz <csteinmetz at yandex.com>
>> Cc: 390 list <r-390 at mailman.qth.net>
>> Subject: Re: [R-390] Cutting Aluminium Plate
>> Message-ID:
>> <CAO-B_TcVc0VZg=L=z-sLvz7+DZSZtV5T2psyjLmbFTCeYX80Kg at mail.gmail.com>
>> Content-Type: text/plain; charset=UTF-8
>>
>> Cut mine out with a hacksaw. Took about 15 minutes. Laminated a photo
>> image of the LC xmfr networks and the alignment blocks into plastic and
>> attached that to the plate. Images came from the Y2K manual. Looks FB. Alan
>>
>> On Fri, Oct 28, 2016 at 12:49 AM, Charles Steinmetz <csteinmetz at yandex.com>
>> wrote:
>>
>>> Perry wrote:
>>>
>>> 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?
>>>>
>>>
>>> 40 teeth is WAY, WAY too coarse to cut aluminum of any kind, and most
>>> especially thin sheets. You need a 100-tooth "non-ferrous metal" blade.
>>> And unless you have a very good table saw, you won't have enough power to
>>> cut aluminum with a 10" blade. Most folks use 7-1/4" or 8" blades for
>> this
>>> (even if they DO have a very good saw).
>>>
>>> Aluminum tends to catch the saw teeth and buck, so you need very good
>>> blade guards that hold the workpiece firmly down on the table, and
>>> anti-kickback prevention.
>>>
>>> Cutting aluminum makes LOTS of noise. Neighbors-may-call-the-police loud.
>>> It sounds like a thousand angry monkeys screaming.
>>>
>>> A metal-cutting bandsaw is a much better tool for this job.
>>>
>>> Best regards,
>>>
>>> Charles
>>>
>>>
>>>
>>> ______________________________________________________________
>>> R-390 mailing list
>>> Home: http://mailman.qth.net/mailman/listinfo/r-390
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>>
>>
>> ------------------------------
>>
>> Message: 3
>> Date: Fri, 28 Oct 2016 05:30:04 -0400
>> From: jbrannig <jbrannig at verizon.net>
>> To: Charles Steinmetz <csteinmetz at yandex.com>, r-390 at mailman.qth.net
>> Subject: Re: [R-390] Cutting Aluminium Plate
>> Message-ID: <jxsswrv62ukvcl3t1h1roikb.1477647004505 at email.android.com>
>> Content-Type: text/plain; charset=utf-8
>>
>> I have used a fine panel cutting blade to cut aluminum on a radial arm saw.
>> The trick is to cut BACKWARDS.....
>> This works with chassis and rack panel thickness.
>> Jim
>>
>>
>> Sent from my Galaxy Tab? A
>> -------- Original message --------From: Charles Steinmetz <
>> csteinmetz at yandex.com> Date: 10/28/16 3:49 AM (GMT-05:00) To:
>> r-390 at mailman.qth.net Subject: Re: [R-390] Cutting Aluminium Plate
>> Perry wrote:
>>
>>> 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?
>>
>> 40 teeth is WAY, WAY too coarse to cut aluminum of any kind, and most
>> especially thin sheets.? You need a 100-tooth "non-ferrous metal" blade.
>> ? And unless you have a very good table saw, you won't have enough power
>> to cut aluminum with a 10" blade.? Most folks use 7-1/4" or 8" blades
>> for this (even if they DO have a very good saw).
>>
>> Aluminum tends to catch the saw teeth and buck, so you need very good
>> blade guards that hold the workpiece firmly down on the table, and
>> anti-kickback prevention.
>>
>> Cutting aluminum makes LOTS of noise. Neighbors-may-call-the-police
>> loud.? It sounds like a thousand angry monkeys screaming.
>>
>> A metal-cutting bandsaw is a much better tool for this job.
>>
>> Best regards,
>>
>> Charles
>>
>>
>> ______________________________________________________________
>> R-390 mailing list
>> Home: http://mailman.qth.net/mailman/listinfo/r-390
>> Help: http://mailman.qth.net/mmfaq.htm
>> Post: mailto:R-390 at mailman.qth.net
>>
>> This list hosted by: http://www.qsl.net
>> Please help support this email list: http://www.qsl.net/donate.html
>>
>> ------------------------------
>>
>> Message: 4
>> Date: Fri, 28 Oct 2016 14:29:19 +0000
>> From: Doug Hensley <w5jv at hotmail.com>
>> To: "r-390 at mailman.qth.net" <r-390 at mailman.qth.net>
>> Subject: Re: [R-390] Cutting Aluminum sheet for your R390
>> Message-ID:
>> <CY1PR15MB0615CE233B721728B91537ED91AD0 at CY1PR15MB0615.
>> namprd15.prod.outlook.com>
>>
>> Content-Type: text/plain; charset="iso-8859-1"
>>
>> Perry, the right way to do that is to have a shop chop it on their cutting
>> shear. If that is prohibitive for you, laying it out with clear marked
>> lines that you can see and using a double cut saw would be easiest.
>>
>>
>> http://www.harborfreight.com/5-in-75-amp-heavy-duty-double-
>> cut-saw-62448.html
>>
>>
>> or an electric hand shear:
>>
>>
>> http://www.northerntool.com/shop/tools/product_200641785_
>> 200641785?cm_mmc=Google-pla&utm_source=Google_PLA&utm_
>> medium=Power%20Tools%20%3E%20Cutters,%20Shears%20%2B%
>> 20Nibblers&utm_campaign=Ironton&utm_content=46257&gclid=CLzhlP3Z_
>> c8CFUUbaQodXH0G_A
>>
>>
>> On a table saw, the blade is going to want to pull on the sheeting if your
>> feed pressure or clamping jig is not right. Then it will try to kick the
>> sheet metal up over itself. Not a good thing to do. To control the sheet,
>> you could sandwich sheeting between two pieces of plywood or pine wood and
>> that will dampen the vibration enough so that you can cut through. But
>> then, accuracy is tough to get that way.
>>
>>
>> The problem is not the cutting of the aluminum, its preparing the sheet
>> metal so that the saw passes through it without moving it. I went to NASA
>> on the Gulf Coast one time for a university I was working for and cut off a
>> twelve foot by eight foot piece of 1 1/8" T6061 with a skillsaw and bottle
>> of spray lubricant. Taking my time, it cut like butter but you see the
>> plate did not move and so the saw just took its sweet time and enjoyed the
>> ride ! The magic is all in the planning.
>>
>>
>> Good luck,
>>
>>
>> Doug W5JV
>>
>>
>>
>>
>> ------------------------------
>>
>> Message: 6
>> Date: Fri, 28 Oct 2016 05:47:35 +0000 (UTC)
>> From: Perry Sandeen <sandeenpa at yahoo.com>
>> To: "r-390 at mailman.qth.net" <r-390 at mailman.qth.net>
>> 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
>>
>> ------------------------------
>>
>>
>> ________________________________
>>
>>
>> ------------------------------
>>
>> Message: 5
>> Date: Fri, 28 Oct 2016 09:56:43 -0500
>> From: Robert Nickels <ranickel at comcast.net>
>> To: r-390 at mailman.qth.net
>> Subject: Re: [R-390] Cutting Aluminum sheet for your R390
>> Message-ID: <12874bec-d0e2-cd09-743e-7949a77c881a at comcast.net>
>> Content-Type: text/plain; charset=windows-1252; format=flowed
>>
>> Some of you may have seen the excellent work my friend Mike KG7TR has
>> done in his ER articles on his homebrewed SSB gear as seen here:
>>
>> http://www.kg7tr.com/
>>
>> Mike gave a presentation at the Jonesborough TN Central
>> Electronics-Vintage SSB gathering this year on his construction methods
>> and tools. He stresses that he doesn't own a brake or shear and makes
>> the panels and cabinets for all this beautiful gear using a square,
>> sabre saw, and "lots of filing". If you're in production, you want to
>> use the right and best tool for the job but if you're a hobbyist making
>> a one-off project, patience and elbow grease are acceptable substitutes.
>>
>> 73, Bob W9RAN
>>
>>
>> ------------------------------
>>
>> Subject: Digest Footer
>>
>> _______________________________________________
>> R-390 mailing list
>> R-390 at mailman.qth.net
>> http://mailman.qth.net/mailman/listinfo/r-390
>>
>>
>> ------------------------------
>>
>> End of R-390 Digest, Vol 150, Issue 29
>> **************************************
>>
>>
>> ------------------------------
>>
>> Message: 2
>> Date: Fri, 28 Oct 2016 13:11:41 -0500
>> From: Bill Guyger <bguyger at yahoo.com>
>> To: Tisha Hayes <tisha.hayes at gmail.com>
>> Cc: R390A <r-390 at mailman.qth.net>
>> Subject: Re: [R-390] Cutting aluminum sheet
>> Message-ID: <2B3B7DB3-47BF-4111-8F4F-C5594EE50DD2 at yahoo.com>
>> Content-Type: text/plain; charset=us-ascii
>>
>> As I mentioned earlier I use a saber saw but I do use a fairly course blade
>> IIRC 14 teeth/inch. Fine toothed Blades gaul quickly because aluminum is so
>> soft (this is of course ignoring the hard alloys that are intended for
>> milling). In other words fine tooth blades get clogged rapidly and cease
>> cutting.
>>
>> Bill AD5OL
>>
>> Sent from my iPhone
>>
>>> On Oct 28, 2016, at 12:40 PM, Tisha Hayes <tisha.hayes at gmail.com> wrote:
>>>
>>> Right out of college I was working for a company that also fabricated their
>>> own custom control cabinets out of aluminum. They used a table saw with a
>>> pretty coarse blade. No guards, no shields, they were dragging these big 4'
>>> x 4' sheets of 1/4" aluminum and one guy would wrestle this through the
>>> saw.
>>>
>>> The entire process horrified me; I was picturing just about every way it
>>> could go bad. Sometimes the metal sheet would ride up and the blade would
>>> cut a nasty gouge on the bottom the sheet as it tried to launch this big
>>> piece of aluminum back in to the belly of the guy who was feeding the
>>> monster. My imagination for how bad it could get would be perfect for movie
>>> making or nightmares.
>>>
>>> When I was making prototypes or test jigs out of a bed of nails with POGO
>>> contacts I had to be in the same room. I made every effort to not be there
>>> on aluminum cutting day.
>>>
>>> From what I recall, the blade had to be riding pretty high off of the deck
>>> to minimize the bucking.
>>>
>>> It also did make a horrendous noise. Even a half-a-building away I could
>>> hear it when they were cutting aluminum.
>>>
>>> *Ms. Tisha Hayes, AA4HA*
>>> *"*There are many who live in the mountains and behave as if they were in
>>> **the
>>> town; they are wasting their time.*
>>> * It is possible to be a solitary in one's mind while living in a crowd;
>>> and it is possible for those who are **solitary to live in the crowd of
>>> their own thoughts.*"*
>>> **-Amma Syncletica of Alexandria**
>>> ______________________________________________________________
>>> R-390 mailing list
>>> Home: http://mailman.qth.net/mailman/listinfo/r-390
>>> Help: http://mailman.qth.net/mmfaq.htm
>>> Post: mailto:R-390 at mailman.qth.net
>>>
>>> This list hosted by: http://www.qsl.net
>>> Please help support this email list: http://www.qsl.net/donate.html
>>
>>
>> ------------------------------
>>
>> Message: 3
>> Date: Fri, 28 Oct 2016 14:30:15 -0400
>> From: Charles Steinmetz <csteinmetz at yandex.com>
>> To: r-390 at mailman.qth.net
>> Subject: Re: [R-390] Cutting aluminum sheet
>> Message-ID: <58139937.8090101 at yandex.com>
>> Content-Type: text/plain; charset=utf-8; format=flowed
>>
>> Bill wrote:
>>
>>> As I mentioned earlier I use a saber saw but I do use a fairly course blade
>>> IIRC 14 teeth/inch.
>>
>> That is extremely fine compared to the OP's blade. Your blade has over
>> 300 teeth (assuming it is a standard 7-1/4" blade), while his has only
>> 40 (about 1.25 teeth/inch).
>>
>> Best regards,
>>
>> Charles
>>
>>
>>
>>
>> ------------------------------
>>
>> Message: 4
>> Date: Fri, 28 Oct 2016 18:32:49 +0000 (UTC)
>> From: Mike Bracey <mikebracey at att.net>
>> To: John Saxon <johnbsaxon at yahoo.com>, "W9RAN at oneradio.net"
>> <W9RAN at oneradio.net>, "r-390 at mailman.qth.net" <r-390 at mailman.qth.net>
>> Subject: Re: [R-390] Cutting Aluminum sheet for your R390
>> Message-ID: <858284706.763874.1477679569850 at mail.yahoo.com>
>> Content-Type: text/plain; charset=UTF-8
>>
>> The quality of his work is amazing! I wish I could come close to his level of
>> craftsmanship.
>> 73, Mike/KE5YTV
>>
>>
>> From: John Saxon via R-390 <r-390 at mailman.qth.net>
>> To: "W9RAN at oneradio.net" <W9RAN at oneradio.net>; "r-390 at mailman.qth.net"
>> <r-390 at mailman.qth.net>
>> Sent: Friday, October 28, 2016 10:34 AM
>> Subject: Re: [R-390] Cutting Aluminum sheet for your R390
>>
>> Just wanted to say...I think Mike, KG7TR, is a homebrew genius. ?I have
>> admired his work for a long time, and I have a folder filled with the info
>> from his website. ?I find it inspirational that he uses tools that are
>> readily available to most of us, and not that expensive.
>> 73,JohnK5ENQ
>>
>> ? ? ? From: Robert Nickels <ranickel at comcast.net>
>> To: r-390 at mailman.qth.net
>> Sent: Friday, October 28, 2016 9:56 AM
>> Subject: Re: [R-390] Cutting Aluminum sheet for your R390
>> ?
>> Some of you may have seen the excellent work my friend Mike KG7TR has
>> done in his ER articles on his homebrewed SSB gear as seen here:
>>
>> http://www.kg7tr.com/
>>
>> Mike gave a presentation at the Jonesborough TN Central
>> Electronics-Vintage SSB gathering this year on his construction methods
>> and tools.? He stresses that he doesn't own a brake or shear and makes
>> the panels and cabinets for all this beautiful gear using a square,
>> sabre saw, and "lots of filing".? ? If you're in production, you want to
>> use the right and best tool for the job but if you're a hobbyist making
>> a one-off project,? patience and elbow grease are acceptable substitutes.
>>
>> 73, Bob W9RAN
>> ______________________________________________________________
>> R-390 mailing list
>> Home: http://mailman.qth.net/mailman/listinfo/r-390
>> Help: http://mailman.qth.net/mmfaq.htm
>> Post: mailto:R-390 at mailman.qth.net
>>
>> This list hosted by: http://www.qsl.net
>> Please help support this email list: http://www.qsl.net/donate.html
>>
>>
>> ?
>> ______________________________________________________________
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>> Please help support this email list: http://www.qsl.net/donate.html
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>>
>>
>> ------------------------------
>>
>> Subject: Digest Footer
>>
>> _______________________________________________
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>> http://mailman.qth.net/mailman/listinfo/r-390
>>
>>
>> ------------------------------
>>
>> End of R-390 Digest, Vol 150, Issue 31
>> **************************************
>>
>> ______________________________________________________________
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