Cutting sheet aluminum ?

[jandtjil]

What is the best option for cutting sheet aluminum without seriously puckering/deforming, yet still have the ability to cut mild radius corners ?

Jig saw with 24-32 blade

or

air / electric metal shears



Am going to install an additional window in our camper trailer, the last tech detail I need to conquer the task, is cutting the outside aluminum siding.



JJ

 

[B.G. Smith]

I don't think either would deform metal that thin too much. If you use the saw, candle wax on the blade will keep it from balling up with aluminum. Best method to apply is have someone hold a candle against the side of the blade while cutting, just make sure and use a long candle so they don't get into the blade. bg

 

[jandtjil]

Thanks B. G.

 

[Hoefler]

Use a pair of good snips. The jig saw will wind up scratching up the paint from the saw base and won't cut very well, the shears will cut very well, but will not radius well at all. Get a set of Swiss sheet metal snips, you will get a left, right, and straight cut. They cut very well and very neat.

 

[tony597fitter]

I like my air nibbler. You can cut tighter radiuses than shears or snips.

 

[cap-n-cray]

If the aluminum is thin use a utility knife and score it several times using a metal straight edge as a guide. It may cut it completely, but it will leave a good cut line. Cut to the inside of the line. Usually there is a sub-surface of wood under the aluminum. If you use a jig saw tape the bottom shoe several time to prevent scratches. Also blue tape the surface of what your cutting that is not scrap. Push the jig saw hard against the surface, so it does not bounce with the cuts.



Good luck.



Cary

 

[JFaulkner]

circular saw with a good carbide tipped wood blade. We work with aluminum sheets quite a bit and there is no better way to do it, it cuts better than wood.

 

[rbattelle]

Oh, man, I'd advise strongly against using a jig saw on aluminum. I tried it once, and swore never to do it again (on a piece of 1/8" aluminum).

I'd take Hoefler's advice.

Ryan

 

[p-Bar]

circular saw with a good carbide tipped wood blade. We work with aluminum sheets quite a bit and there is no better way to do it, it cuts better than wood.

Just be sure the blade has negative hook to it. The teeth will look like they are laying back on the blade

 

[RMarkey]

Last time we cut aluminum at the shop, I think the guys used the plasma cutter, worked well, smelled bad though.

 

[JFaulkner]

Just be sure the blade has negative hook to it. The teeth will look like they are laying back on the blade

Absolutely not. A regular carbide wood blade works flawlessly. I didn't believe it would work but a guy at M. H Eby told me to try it so I did and I haven't used the plasma cutter since.

 

[p-Bar]

Absolutely not. A regular carbide wood blade works flawlessly. I didn't believe it would work but a guy at M. H Eby told me to try it so I did and I haven't used the plasma cutter since.

If there is too much hook in the blade Which I'm not sure you are understanding ,it will grab the aluminum and tear it .

 

[JFaulkner]

If there is too much hook in the blade Which I'm not sure you are understanding ,it will grab the aluminum and tear it .

I understand what your saying and I didn't think it would work either, but it did/does. I'm not trying to argue with anyone, you can cut it with a butter knife if you want. We built 3 of these custom hopper/flat trailers cutting all the aluminum with a $50. 00 circular saw. Cut the factory floor out, all the hopper slopes, and the replacement removable floor panels.

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[rbattelle]

Wow, now that's some metalworkin'! Nice trailer! Are those rivets or bolts hold that thing together?

Ryan

 

[jandtjil]

Thats what I'm talkin about, many responses.

Hoefler
Looking at my trlr blueprints, both vertical cuts will be made on the inside edge of an existing wall stud. Right up against the stud, will the snips cut a clean/semi clean edge up against this? I haven't worked with sheet metal in a long time, wood Yes, metal No.

tony597fitter
About a quarter century ago I used a nibbler doing some body work. I am guessing it would perform better against alum, than I remember against steel.
Any brand recommendations?

RMarkey
I think to eliminate the smell you have to mount the plasma cutter on a shark

JFaulkner
Circ saw, I have read in other forums, it works! Still having doubts though, trailer siding is so thin, yet that may be exactly why it will work so well.

cap-n-cray
If it is was flat un-corrugated siding, the utility knife would probably be my 1st choice. Brilliant! Trailer siding is very soft/thin. I'll have one handy, good idea!

If it was stored inside, I wouldn't be stressing quite so much, but I want to cut, re-brace and seal in one day. No surprises! Even if I go out and buy a nibbler, two new circ blades a dozen jig saw blades, pearl handled snips and hire an assistant, it will still be hundreds of dollars cheaper than paying to have it skinned and a window installed.
Unless I screw it up terribly:E If so, my next post will be "best tool for B@ll removal by spouse?"

JJ

 

[Hoefler]

Thats what I'm talkin about, many responses.



Hoefler

Looking at my trlr blueprints, both vertical cuts will be made on the inside edge of an existing wall stud. Right up against the stud, will the snips cut a clean/semi clean edge up against this? I haven't worked with sheet metal in a long time, wood Yes, metal No.

In a word, yes. When I was in a RV shop, we also used a trim router with a carbide laminate trimming bit. The snips is the most economical way for the do it yourself-er, unless you have the power tools already. A good bit with follower bearing will set you back about $30. 00. You can also use a RotoZip as well.

 

[jandtjil]

I had no idea a roto blade would cut metal, I just checked the site and they make a bit specifically for light metal. I had already planned using it for the interior, but it never crossed my mind for the exterior alum. Genius!

I think I will purchase a set of snips as you earlier suggested, but I will certainly try the Roto. Thanks Hoefler. Thanks to all of the other responses too, exactly why I never hesitate to renew. The members make this place special.



JJ

 

[SSell]

circular saw or table saw works well, been told aluminum cuts nearly same as hard oak this way.



FWIW...

 

[JFaulkner]

Wow, now that's some metalworkin'! Nice trailer! Are those rivets or bolts hold that thing together?



Ryan

Stainless bolts hold the actual hopper sheets to the frame rails. Every other panel is held with buck rivets, lots and lots of rivets. :{

 

[sdstriper]

What is the best option for cutting sheet aluminum without seriously puckering/deforming, yet still have the ability to cut mild radius corners ?

Jig saw with 24-32 blade

or

air / electric metal shears



Am going to install an additional window in our camper trailer, the last tech detail I need to conquer the task, is cutting the outside aluminum siding.



JJ

I vote for the snips and drill a hole to get started, last thing I would want to do is muck up the exterior of my camper if I had a booboo with power tools... Unless your an accomplished metal worker etc. Then by all means fire up the pwr tools. That is some thin metal your working with, it will tear pretty easy, and cut easy too. How thick is the actual wall thickness? Something to consider if using pwr tool.