Cutting aluminum

[AlphaTeam]

Hi I posted my project in the projects section; the thing is I need help cutting aluminum and without knowing what do use what is best way to cut a 3-inch square into 3 mm thick aluminum sheet?

Here's my project: http://www.thebestcasescenario.com/forum/showthread.php?p=187916

[mtekk]

It depends on what you have available. Arguably the best way would to start by marking the hole, then you can drill a hole in the center (don't want it right on the corner if the piece you are saving is the sheet, not the part from the hole). Then use either a scrool saw with a metal cutting blade (I prefer this as it has a built in table/stand so you only have to move the material around), or a jigg saw and use the hole as the start of your cut. Naturally, the hole needs to be big enough to fit the saw blade ;). You could also use a dremel with a cutting disk, but using a saw is more economical (if you already have one).

[AlphaTeam]

I did buy a dremel and I don't have a saw.

What is this cutting disk? You mean small circular cutting blade? I was told have a carbide cuttter will work.. does it?

[mtekk]

Yes, the carbide blade should be much better, though I don't have one so I can't confirm that. I suspect it probably doesn't wear like the normal cutting disks do. With the dremal, since you are cutting with a circular blade, you will want to start by drilling holes in each corner, then cutting from the back, connect the holes. Be aware that the round disk doesn't cut straight down, so the lines cut on the inside will be longer than those on the outside.

[crazybillybob]

The best way to cut a 3" solid Square into 3mm Sheets would be with a band saw, but you'd have to cut it a but over sized then file, scrape, sand it down to 3mm so that the surface finish was nice. 2nd method would be use a hack saw, still going to need to over size it then sand it smooth.

Dermel going to be tough to use as the biggest cutting wheels for metal are 1.75" in dia... which means you can only cut a max depth of .875" (half the dia of the blade) even if you cut from all 4 sides you'll not be able to reach the 1/4-1/2" bit in the middle, plus your going to go through allot of cutting discs, and they aren't cheap.

If money is the object you can get a hacksaw from your local hardware for about $10us.

Good Luck,
CrazyBillyBob