[R-390] Cutting Aluminum With Power Tools

[Perry Sandeen]

Yo Bubba Dudes!
A while back I posted a request for advice for cutting aluminum sheet with power tools (OK nitpickers it was a long time ago).
I received many good responses of advice.
I recently had to cut up a number of chassis' and plates so this is how I did it using both a hand skill saw and a cutoff (chop) saw.
First and foremost: WEAR EYE PROTECTION. The shavings are sharp and travel with both a surprising distance and velocity.  A couple hit my cheek and it was not a pleasant feeling. 

I installed a new 10 inch, 40 tooth carbide red *Diablo* blade in the normal direction.  I briefly considered buying an 80 tooth one but decided it was too expensive.
Going slowly I got mirror finish cuts. any burrs can re removed with a fine file or 220 grit sandpaper.

On some of the thinner material I placed it on top of scrap wood so there was no chatter.  This is a judgement call but with the normal blade gap that comes with the saw using a scrap under piece is preferred.
On my hand skill saw I also used a new Diable 40 tooth carbide blade and got equally good results.
I also had some hobby aluminum sheets from Do-It-Best (a mirror of Ace Hardware stores) that were IIRC .019 inches. I did not try to cut them with power tools.  I think the only safe way to cut them is to sandwich them between two pieces of at least 3/4 plywood.
I found out that time wise, it was better to clamp the piece down on scrap OSB, clamp a straight edge along the desired cut line then use a large Dewalt retractile blade knife and repeatedly score the edge using light to moderate force.  It's a learn by doing technique only.The cut lines are easily smoothed with a small flat jewelers file or a bit of emery cloth sandpaper.
At this time I don't have access to a table saw but I suspect with the same carbide blade setup and doing a slow feed I'd get the same results. 

YMMV
Regards,
Perrier