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?'s about cutting .060 aluminum with utility knife...
- Thread starter iSign
- Start date
skyhigh
New Member
Use your circular saw. Being that you allready have the 2x4's and clamps out, USE THEM AS A GUIDE for the circular. You will not have ragged edges!!!!
The only material I found suitable for cutting with a utility knife is dibond (or one of the similar products). Even at that, the material will be left with a razor sharp edge that will need filed down. For the thinner aluminums (on larger bends) you will almost always get some distortion of the material while bending. For the thicker materials....well, you allready found out how well that works.
The only material I found suitable for cutting with a utility knife is dibond (or one of the similar products). Even at that, the material will be left with a razor sharp edge that will need filed down. For the thinner aluminums (on larger bends) you will almost always get some distortion of the material while bending. For the thicker materials....well, you allready found out how well that works.
Wes Phifer
New Member
Panel saw works good. A little rough on the edges but it is not bad. Works better on thicker aluminum than .040.
UFB Fabrication
New Member
type in the back gage on the shear, turn on insert material step on peddle clunk and its done. clean easy no chips no muss no fuss. plan B cut on router, plan c cut on panel saw. plan d have someone else cut it.
skyhigh
New Member
That is the "ideal" way for sure! For those that don't have a shear, perhaps you have a metal fabrication shop on the island near you.
UFB Fabrication
New Member
Maybe you could mask off both sides of it leaving 1/8'' of space on either side. Insulate with super insulation and drop dry ice in the area to be cut. Then get the biggest stereo system around and play Barry Manilows greatest hits until it shatters right along the line to be cut. 
G-Artist
New Member
Most of us don't have to cut aluminum or other metals very often as we usually get it cut to size but there will be times it is better to buy a full sheet or you need a special shape.
The following works for both a circle saw and a jigsaw.
Cutting a shape with a hand-held jigsaw - place a full sheet of styrofoam under the entire panel and tape the panel to it. It fully supports your cut and you now eliminate the "chatter" and you can easily turn it from time to time on your work table.
For a straight cut all you need is a slice of styrofoam the length or longer than your cut and a few extra pieces to keep the panel level.
It will not dull cutting blades and a shop vac will gather up any scree.
Styro panels can be purchased in places like Home Depot, Lowe's,etc. as well as from plastic supply houses.
We use the stryo method to cut all thin stocks regardless of what they are. I have had the same piece of styro in my shop for about a year now. I think it cost about $20 for the 2" thick stuff. Lot less for the 1/2" stuff.
The following works for both a circle saw and a jigsaw.
Cutting a shape with a hand-held jigsaw - place a full sheet of styrofoam under the entire panel and tape the panel to it. It fully supports your cut and you now eliminate the "chatter" and you can easily turn it from time to time on your work table.
For a straight cut all you need is a slice of styrofoam the length or longer than your cut and a few extra pieces to keep the panel level.
It will not dull cutting blades and a shop vac will gather up any scree.
Styro panels can be purchased in places like Home Depot, Lowe's,etc. as well as from plastic supply houses.
We use the stryo method to cut all thin stocks regardless of what they are. I have had the same piece of styro in my shop for about a year now. I think it cost about $20 for the 2" thick stuff. Lot less for the 1/2" stuff.