Cutting/Trimming Aluminum panels ? ?

[Mike_La]

I recently picked up 4'X10' aluminum panels to use for the siding on my TD build. My original thoughts were to mark the trailer profile on the panels and have them cut by water-jet. I know this would make a clean cut, but was wondering how most folks(using aluminum for siding) trim the side profile. Now, I have trimmed sheet metal and flashing using shears/snips, but was mostly for jobs that were for function, not for show.
I'm looking for tips and techniques, you may have, for doing a clean job at cutting/trimming.



http://www.tnttt.com/viewtopic.php?t=32417

[Mike Angeles]

Etech-
I cut my rough profile with a Jigsaw and cleaned up the edge with a flush trim bit on a Router. very clean, Id recommend a lower speed on your router as it tends to melt or gum up.

Mike

[bobhenry]

I was recently introducer to a pneumatic nibbler. Think of it as a air powered paper punch gone beserk. I think if the side was there to act as a template it would do a fine job. I was surprised how inexpensive they were.

http://search.harborfreight.com/cpisearch/web/search.do?keyword=nibbler&Submit=Go

[Nobody]

Mike, I used a cheap Sheet Metal Shear from Harbor Freight. Clamped my 'skin' panels in place on the TD & marked the profile. Used the shear to cut 'em a quarter inch or so larger then 'secured' 'em in place with construction adhesive (yeah, I know it'll separate from different temps between wood'n aluminum but it wuz only temporary 'til door'n edge trim installed) & a few staples/screws along edge. I then used a cheap (like that word cheap ) trim router also from HF, to trim the skin edge flush with the wall profile. One tip, use the largest diameter 'flush trim bit' that your router will handle & if you don't have a variable speed trimmer, go SLOWLY...! The larger bits won't clog up as badly as the small 1/4" ones will. Also, I found that a single flute bit usually works better than a multi-flute bit. Again, go SLOW, else you'll spend a lot of time cleaning aluminum dross from the bit(s). Think I paid almost as much for the flush trim bit as I did the router but it wuz worth it in efficiency. Bought both the router & shear on sale & used %-off coupons, don't think I paid much over $20 for either in 2006.



18 Gauge Sheet Metal Shear

Make smooth clean cuts through sheet metal, aluminum and plastic as thick as 18 gauge. Includes one set of carbide blades, extra carbon brushes, hex key.

* Easy on/off thumb switch
* Throat depth: 5/8''
* Tungsten carbide cutters for long life


120V, 60 Hz, 1.5 amps
Weight: 5.85 lbs.


ITEM 92148-3VGA

$39.99

1/4" Trim Router

* High-powered, lightweight tool delivers impressive wood-trimming power
* Cutting depth adjusts easily for accurate cuts every time
* Maximum speed: 26,000 RPM
* Standard 1/4" collet accepts most router bits


120 volt, 2.4 amp motor; Includes straight guide
Tool weight: 2-1/2 lbs.


ITEM 44914-0VGA


$21.99

[planovet]

I cut my rough profile with a Jigsaw and cleaned up the edge with a flush trim bit on a Router. very clean, Id recommend a lower speed on your router as it tends to melt or gum up.

That's what I did and it worked well.

[aggie79]

Timely post. Thank you.

I'm hoping to be cutting aluminum in about a 1 1/2 weeks.

[Mike_La]

I want to thank all who have replied. All are of great help.

I don't own a router, but do have a RotZip. Can I possibly purchase a RotZip bit to do the finish trim. I guess I'm getting ahead of myself with this question. I will look into 18 Gage Sheet Metal Electric Shear that Nobody spoke of, then do the final trim with the RotoZip, if there is a correct bit available

[Nobody]

Mike, I know they have 'laminate trim' bits for the Rotozip. If that bit has the guide bearing on outer end, betcha it'll trim your skin panels. All the Rotozip bits I've seen are pretty small, 1/4" or so & will require very slow feed.

[afreegreek]

use a 1/2" diameter flush trim bit. no need to pre cut it either. just make sure it won't move on you and support the cut off as you go. it's good to use some lube on the bit too. PAM cooking spray works real good and it's cheap.

[afreegreek]

I want to thank all who have replied. All are of great help.

I don't own a router, but do have a RotZip. Can I possibly purchase a RotZip bit to do the finish trim. I guess I'm getting ahead of myself with this question. I will look into 18 Gage Sheet Metal Electric Shear that Nobody spoke of, then do the final trim with the RotoZip, if there is a correct bit available

save your money and don't but the nibbler or shear, you don't need it for this job, buy a trim or regular router instead. I saw that rotozip sells a 1/4" collet so you can but a regular flush trim bit if you have the rotozip already.

[Mike_La]

I want to thank all who have replied. All are of great help.

I don't own a router, but do have a RotZip. Can I possibly purchase a RotZip bit to do the finish trim. I guess I'm getting ahead of myself with this question. I will look into 18 Gage Sheet Metal Electric Shear that Nobody spoke of, then do the final trim with the RotoZip, if there is a correct bit available

save your money and don't but the nibbler or shear, you don't need it for this job, buy a trim or regular router instead. I saw that rotozip sells a 1/4" collet so you can but a regular flush trim bit if you have the rotozip already.

I do have the 1/4" collet.

[Mikey1975]

what kind of router bit do you all use i know aluminium trim bit but what brand???

[afreegreek]

I want to thank all who have replied. All are of great help.

I don't own a router, but do have a RotZip. Can I possibly purchase a RotZip bit to do the finish trim. I guess I'm getting ahead of myself with this question. I will look into 18 Gage Sheet Metal Electric Shear that Nobody spoke of, then do the final trim with the RotoZip, if there is a correct bit available

save your money and don't but the nibbler or shear, you don't need it for this job, buy a trim or regular router instead. I saw that rotozip sells a 1/4" collet so you can but a regular flush trim bit if you have the rotozip already.

I do have the 1/4" collet.

cool, now just buy a 1/4" shank flush trim bit in 1/2" diameter and you're set. you can buy a really cheap one too, no need to spend the money on a Frued or some other premium brand. that matters if you're trimming wood and need a really sharp bit to prevent tearing out the grain.. at our shop we use the cheap ones for metal and plastic laminate and they work just fine.

when you're cutting, set the bearing lower than you need to by about an 1/8" or more so the aluminum cut off won't get into that gap between the bit and the bearing as it sags.

[Mikey1975]

You talking crap about FREUD LOL thats what i got

[afreegreek]

what kind of router bit do you all use i know aluminium trim bit but what brand???

any single flute or dual flute bit will work, any brand as well. this is what they look like...

http://www.freud-tools.com/freudbearflu.html