how-to cut aluminum

[azz7772]

hey all need some more advice I purchased some diamond plate aluminum and plan on making a gauge cluster and have it wired to be able to unplug from the wiring harness and the ability to work on the gauges on the bench. My question is are there any special tricks or tips on making nice cuts to aluminum? I have to cut the rectangle size out and then the gauge holes. Can I use a jig saw with a special blade? And a hole saw for the holes?

[mark m.]

Yes you can on both tools. If it is possible to do all your layout and cutting on the backside of the plate do it. It keeps the front front unwanted scratches from the jigsaw. If not use a couple layers of masking tape on the front to minimize this.

Also jigsaw blades don't need to be special. Just pick one with about 18 teeth per inch an use WD 40 for a cutting lube. A medium cut file will clean up the rest.

We want pics when it's done

[racerone3]

A table saw also works really well. Tape it up like Mark said and go at it

[azz7772]

ok thanx I will post some pics when I get to it

[Rock Doctor]

I've always used a Skill Saw. I've heard guys say that you should flip the blade around for aluminium, but never bothered with that. Just make sure you have VERY good eye protection when cutting Aluminium this way...........VERY GOOD.


RD

[azz7772]

I've always used a Skill Saw. I've heard guys say that you should flip the blade around for aluminium, but never bothered with that. Just make sure you have VERY good eye protection when cutting Aluminium this way...........VERY GOOD.
RD

does it matter on tooth count I know more would be better but will any blade work?

[mark m.]

Let's talk jigsaw. Like I said earlier 18 tooth or maybe a variable pitch (12-14) blade works well for the thickness of material you will be cutting. Along with the cutting fluid WD40. The WD keeps the teeth from loading up. The fastest speed is not always desirable. Perhaps half to three quarters throttle on the saw.

Now circular saws, (not to take away from what RD mentioned).Using a Skill Saw or equivalent I have cut inch and a half thick 6061 aluminum with a heavy duty worm gear circular saw with a 60 tooth carbide blade. The mess and the noise is something see and hear.
I would stick with the jig saw approach for what your doing. Easy peasy.

[Rock Doctor]

Now circular saws, (not to take away from what RD mentioned).Using a Skill Saw or equivalent I have cut inch and a half thick 6061 aluminum with a heavy duty worm gear circular saw with a 60 tooth carbide blade. The mess and the noise is something see and hear.
.

Very true, I agree completely, the noise is extreme, and the mess is worse, but if you have a lot of material to cut, (for me) speed is worth the noise and mess.

RD

[Jeff t-boss]

As the members mentioned, It is recommended to use the jigsaw and coat both sides of the plate with masking tape to protect from scratched. I might add that you would want to use a slower cutting (Blade) speed and lightly work the tool so IT does the cutting and you don't clog the teeth. A medium blade is fine for this even if used dry. If you have access to one, you can also use a vertical bandsaw. Same rules apply as if useing a jig/sawsall. Also gives you a more consistant cut, as it reduces the minute jarring from the reciprocation and vibration of the other saws. As far as hole sawing the gage holes goes, I (In any material) have found it to leave a much more cleaner and accurate hole if you first drill your (Usually 1/4 inch) pilot hole through the material. (Make sure it is square all the way through.) Then remove the bit and install a 1/4 inch piece of roundstock in it's place (In the hole saw you are useing). Drill 1/2 way through the material on one side, then flip it over and finish the bore. Again, keep your rpms down, and don't use too much pressure. Makes for a much cleaner and precise cut/hole. Then you can dress the bore with a round file as needed.

[azz7772]

here are some pics of the work i have done so far i still have some file work then wireing the space in the middle of the guage cluster is for a tac if i can find one to work with my kabota diesel.
thanx again for the advice worked excellent.

http://s154.photobucket.com/albums/s... for predator/

[azz7772]

custom instrument cluster

hi all when I bought my predator it was missing gauges and the ignition was just hanging down so I decided to make one. Here is what I got so far I plan to pre wire the cluster and have it so it will just plug into the wire harness.the space in the middle is for a tac .....if I can get one to work with my kabota diesel. Thanx to 6x6 world members with advice

http://s154.photobucket.com/albums/s279/azz7772/instrument cluster for predator/

[guyfox]

I think you are going to have a nice looking panel when you are finished....It will look really good on the machine....

[renegade83]

Can't wait to see pics