Cutting Aluminium

[simon]

I need to cut some aluminium angle in to lengths of 100mm for heatsinking. I'm thinking of using 2" x 1" x 1/4" angle. What's a good way of cutting it efficiently and neatly? I could have 10 of these cuts so don't really want to battle away with a hacksaw if I can help it.

I did wonder about a blade for my chopsaw but haven't seen anything obvious and the blade would be expensive no doubt. Alternatively I could use a power jigsaw which would probably be quicker than a hacksaw but need a fair bit of tidying up after. Time is a premium commodity for me so any suggestions gratefully received.

[pre65]

Jigsaw with the right blade would be quickest.

Hacksaw with the right blade is second best, should not take too long to do.

Fettle up with a medium file.

That's how I do it.

[ed]

Simon, if you've got a chop/circular saw then choose it every time over a jigsaw if you want to cut straight lines:

http://www.toolstation.com/shop/Power+T ... 137/p38247

jigsaws are for propping open the shed door!

[pre65]

jigsaws are for propping open the shed door!

May be so for professional use, but us amateurs have to use what we've got to hand.

I don't really subscribe to the theory that you can't cut straight lines, just needs a bit of care.

Each to their own, but my personal preference would be the hacksaw.

[simon]

Oooh Ed, I like that, and the price. But is it a blade for cutting aluminium or a blade made from aluminium? The descriptions suggests it's for cutting wood and composite materials? But if it's not going to break up on use for a tenner it doesn't have to last too long.

Thanks for the advice Phil, what would be the correct blade for a hacksaw for this amount of cutting? Does it need any lube or is that just drilling?

[pre65]

Depends on the type of Aluminium.

I use a 24 TPI blade for the sort of Aluminium I use (engineering grade) but softer grades may be better with fewer teeth per inch, like 18.

I purchased a bundle of Sandflex bi-metal blades off e-bay a while ago and they cut brilliantly and last a long time. Well worth the extra cost. I don't use lube when cutting or drilling Alloy.

Just beware of bog basic no name blades, they are (generally speaking) frigging useless.

PS something like this

http://www.ebay.co.uk/itm/10-x-SANDFLEX ... 1165wt_932

[Ali Tait]

24 or 18 TPI blades will cut ally fine Simon. Or post them to me and I'll do them with the chopsaw at work!

[Toppsy]

Simon,
These do a FREE CUTTING SERVICE
I've used them in the past and they were quick to deliver.

http://www.forwardmetals.co.uk/

[ed]

Hi Simon

Colin's suggestion looks like the bizz, but if you've already got the angle then it's not ideal.......From the first link I gave here's another without the ambiguity...but you'll have to check anyway, to get the right arbor size:

http://www.toolstation.com/shop/Power+T ... 137/p47948

[simon]

Thanks for the advice chaps. I reckon one of those blades should do the job ed . Might just get some of those blades too.

[Mike H]

I've just done it with just a junior hacksaw and put up with the repetiveness

[pre65]

I've just done it with just a junior hacksaw and put up with the repetiveness

You making up new words again ?

Don't you own a "proper" hacksaw ?

[Mike H]

So I spelt it slightly wrong.

http://en.wiktionary.org/wiki/repetitiveness

And yes I do.

But for ally angle, junior hacksaw makes thinner cuts and I find more accurate.