Boat Forum / Building / March 2006

Aluminum is a soft metal and can be cut with about anything. In fact
you could use a hand saw with a fine tooth blade.

Using power tools You will encounter two problem areas.

First, heat buildup caused by friction. A skill saw intended for
cutting wood may have a higher blade speed then ideal for cutting
aluminum.

There second problem you may encounter is that if the aluminum is one
of the softer variates it will tend to clog the saw blade.

I would suggest, if possible, you use a sabre saw with variable
speed.. High speed steel blades will be quite adequate. You don't need
carbide tips although if you do use the skill saw the carbide tips
will withstand the heat better.

The ideal lubricant to use is "Tap Magic" which is a product developed
for tapping screw holes and it really does work like magic. Just be
sure to specify that it is for aluminum.

If you don't want to go to the bother of  locating tap magic a
"secret" I was taught during my apprentice days was to use kerosene or
diesel fuel as a cutting fluid for aluminum. Use a "squirt can" and
give it a squirt from time to time.

Anon
(k4556@inet.co.th)

I cut aluminum with a table saw all the time. I don't even use a blade
meant for aluminum.

Paraffin will work, just a little is enough. More important is feed
speed. Too much and you will heat the blade, warping it.

On my table say I use a triple chip non-ferrous blade and can easily cut up
to half inch.  I use WD40 as the lubricant nut paraffin will work.

I'v been watching a friend of mine building the same thing for the last
year. I was amazed.... he just used common wood working tools. No
lubracant at all.
Bob.

As everyone has mentioned, standard wood working saws work.  The primary
thing to worry about with aluminum (other than the mess) is drilling
...marine aluminum can work harden pretty quickly if you get it wrong, then
it becomes very difficult to drill.  Use the lube, use a moderate speed, and
don't push it through the aluminum too slowly ...get the bit to bite.  As
long as the aluminum is cutting, you're fine.  If it stalls ...don't let the
bit sit and spin, but stop, lube, make sure the bit is sharp and try again
but make sure you do what you need to to get the bit to cut metal, not just
spin around on it.

Brian D

Many years ago, GE had their research lab study the question of lubricating
aluminum.  Their conclusion?  Iodine might help a little, but nothing really
worked well.  Tap Magic, kerosene, lard, etc. will cool the blade, but they
won't provide true lubrication like you'd use between the crankshaft and the
connecting rod bearings of an engine.

Roger
derbyrm@NOSPAMinsightbbNOSPAM.com
http://home.insightbb.com/~derbyrm

@#@

I use a product called Do -All it has been around for ages works on all
metal cutting applications , drill bits reamers, saw blades etc. It is an
waxy compound you just smear onto cutting tools works wonders.

Ray