Teardrops n Tiny Travel Trailers

I have to start cutting the aluminum skin for the vents and windows. Jig saw doesn't work. Sawsall missing. Fire ax, errr maybe not the right tool. Was thinking that Aviation snips might be all I need and be easier on my nerves. They make them with various offsets, up to 90 degree. Left and right. Any suggestions? The offsets seem intuitively at least to be easier to use. But I've never cut window or vent holes in trailers. I saw some decent ones at Sears.

Aviation snips work for me for short distances, but then I get into the edges trying to remove my skin. For something like doors and windows, I have been using one of the counter-rotating saws http://www.harborfreight.com/5-in-double-cut-saw-68316.html. It seems to go through the side of my cargo trailer like butter, leaves a clean edge and is really quick. The saw also works on wood and steel. Like you, I had tried the jig saw ans well as my cordless mini-sawzall. The circular saw was much cleaner and easier to handle. You can usually get it on sale, or with a discount.

Pneumatic metal jigsaw from harbor freight. $17 on sale.

My jigsaw with wood cutting blade worked great. I just turned off the blade oscillation, so the blade only moved up and down. I thought I might have to switch to a metal cutting blade, but the wood cutting one cut like butter.

If you don't want to scratch the aluminum, cut on the back side. If you have to cut on the front side, tape it with painters tape.









For most of my aluminum cuts, I used the jig saw for a rough cut (within 1/4 inch) then fine cut in place with a router and flush cut bit.

My jigsaw has worked well for my aluminum skin. Way better than my reciprocating saw which was hard to make smooth corners. I thought about aviation snips too. Has anyone tried those? I'm not sure they would be as maneuverable as the jigsaw, but the cut would probably be cleaner.

sbshaver, Howdy;

Don't know if you have a compressor but, if you have a small shop sized one you
may explore the thoughts of using some of these;
http://www.harborfreight.com/air-tools. ... goryExpand

The shears near the bottom of the page are nice, be sure to use gloves when using them.

hank

For straight cuts in the aluminum I like using a circular saw. Rounded cuts I used a pneumatic auto body saw from HF.

Electric or air shears are nice, but with a fine-tooth wood blade in the jigsaw that you already have, you should be able to get it done. Metal blades in the jigsaw will just clog up.

Thanks to all for these insights for cutting aluminum. In a few weeks, I will cut holes in my CT for 2 windows and one vent.
It scares me a lot. I am afraid of mistakes. I have some building flashing lying around which I will practice on.

I have a jigsaw, new sheet metal clippers, and a new dual action (HF) electric cutter. So I should have the tools needed.

hankaye wrote:sbshaver, Howdy;

Don't know if you have a compressor but, if you have a small shop sized one you
may explore the thoughts of using some of these;
http://www.harborfreight.com/air-tools. ... goryExpand

The shears near the bottom of the page are nice, be sure to use gloves when using them.

hank

Do those Harbor Freight sheers work pretty well? I've had mixed results with HF air tools.

Mike S. Howdy;

Can not vouch for those in particular, but I've used some that looked
exactly like them back in the 70's, 80's and the 90's when i was in the
Navy and worked for a Gov't. contractor. Good results, easy to operate
and from reading the write-ups on HF these will work. That's just my
opinion so take it for what it cost ya.

hank

I framed my windows by filling the wall with plywood about 3 1/2'' bigger than the window all the way around. Then I used a finish cut blade in my Skill saw set just deeper than the total wall thickness. I cut from the inside and then finished the curves with my jig saw using a fine metal cutting blade. It worked really well for me and and was fairly quick. My walls are 1'' thick so I glued 2 layers of 1/2'' plywood together to fill them. I also attached the plywood to the wall studs with screws. It appears to be very strong and also gave me backing all around the windows to attach things like curtain rods easily.

I was the Look trailer dealer today, the manager said they use Aircraft snips to cut the skin on the walls and small sawsall for roof vent cuts.