Cutting aluminum sheeting

[exminnesotaboy]

Can someone help me with options for cutting the .032" aluminum sheeting?

- can I use my Makita jigsaw with a metal cutting blade? will I burn it out or go through too many blades to make it worth while?
- how about electric shears? probably the el-cheapos at Harbor Freight(40$) as I will not ever use them again after this project
- clearly, the best option would be air shears. I know they are easy to use, but I just can't justify the cost of buying an air compressor to run it, and never needing it again - plus no place to store it after the project is complete.

I have friends that will lend me a compressor for the weekends, but they are all the pancake/nailer compressors and I don't believe they will keep up the volume needed for the shears - but they will work great for a brad nailer

In January/February, I will be building a Kuffel Creek Cubby. For the next couple of months, I am learning as much as I can, collecting tools, obtaining materials, etc.... this board has been invaluble to me - Thank You!

[mikeschn]

Using a jigsaw worked out pretty good for my on my first teardrop!



Mike...

[DanD]

Can someone help me with options for cutting the .032" aluminum sheeting?


I have friends that will lend me a compressor for the weekends, but they are all the pancake/nailer compressors and I don't believe they will keep up the volume needed for the shears - but they will work great for a brad nailer

In January/February, I will be building a Kuffel Creek Cubby. For the next couple of months, I am learning as much as I can, collecting tools, obtaining materials, etc.... this board has been invaluble to me - Thank You!

I have a pancake compressor in my shop and if you use it in short bursts, you can run air tools. I mounted my axle, tires and wheels with an air gun running off the little compressor just the other day.

I, too, am building a Kuffel Creek Cubby

[Clancy Courtney]

I cut the profile out with the Al panels sandwiched between the 3/8" plywood with a jigsaw. It cut very well. I also used the HF air shear with my pancake compressor. It couldn't keep up. I bought a HF electric shear and it cut .032" easily. The electric shears krinkled the edge but maybe I didn't use the correct technique. I also cut some on the tablesaw again sandwiching the Al between scrap 1/8" plywood and had good results with carbide tipped blade.
Good luck,
Clancy

[DanD]

. I also used the HF air shear with my pancake compressor. It couldn't keep up.

Other than the compressor not keeping up, how well did the HF air shear cut?

I think they just put it on sale.....

[DanD]

. I also used the HF air shear with my pancake compressor. It couldn't keep up.

Other than the compressor not keeping up, how well did the HF air shear cut?

I think they just put it on sale.....

[Stephen G.]

Hello,
Can you use a router to cut and trim aluminum sheet?

Stephen

[exminnesotaboy]

excellent - it looks like I can use my jigsaw and pick up an electric shear if need be

thank you to everyone for the quick feedback!

Anthony

[Denny Unfried]

Hello,
Can you use a router to cut and trim aluminum sheet?

Stephen

I used a router with ¼" straight carbide cutter for all my aluminum cuts. With a variac I lowered the voltage to 40V to slow the cutter and prevent melting the metal. Of course you have to use a router collar to follow the profile and this leaves a very clean cut. Also there are a few pics on my web site.

Denny

[Clancy Courtney]

DanD, The air shear cut very well. It was just a slower process waiting for the compressor to build back up.
Clancy