Cutting "sandwiches"

[coreyjhen]

I have seen several sites referencing sandwiching aluminum between plywood when cutting out side walls. My question is, what kind of blade do you use when you do that, and what kind of sandpaper will stand up to finishing the edges?

[madjack]

Corey, one of the nice things about AL is that it's soft enough to work with the same tools that you work wood with...the only problems I have found is that you need to go a little slower and the AL saw dust is a little more intrusive (it sticks to and into stuff) and more care needs to be taken with protective gear(eye/face shields, long sleeves, gloves) which should be done regardless of material worked...
madjack

[Clancy Courtney]

Corey, When I cut my sides out (3/8" A-C, .032, .032, 3/8" A-C sandwich)
I used a 8TPI blade in my jigsaw and went slow and careful. The edge didn't need cleanup. If you have a saw with a vacumn port it should help. Mine did, just didn't have shop vac at the time.
Good luck,
Clancy

[jay]

why try? cut the wood sides to the correct profile, adhere the aluminum, and then use a carbide flush cut router bit [bottom bearing] and touch up with a flat mill file.