Michael replied:

Hi there, jig saw and file could be ok , depending on your proficiency, or you can buy a saw similar to a wood saw that takes a hacksaw blade on the leading edge, use a 18 teeth per inch not the finer 32 teeth. Good luck Michael

Member - JohnR (Vic) replied:

G'day scotthomewood Guillotine or plasma cutter - the former is better. You can buy a fine saw blade for a drop saw or any rotary saw that is very fast and quite clean on most metals including steel bar or plate. Mine was about $130 for the blade I think, tungsten carbide tipped for a 9" saw. Wow, will it cut!

An angle grinder at home will tend to tear and roughen the edges unless you use animal fat in the sides where abrasion is likely to take place. You may get a good nibbler to do the job but I have little knowledge of them.

Member - Bradley replied:

you can get carbide tooth wheels for grinders $$ but the best for home would be a metal blade in a jigsaw 18 or 24 tpi and take it slow. finish with a file if needed. you can also linish ally. or of course bandsaw..

NEVER use any sort of grinding or cutting disk or wheel on non-ferous metals as you will clog the disk and can cause the disk/ wheel to explode . very dangerous... Stick to the jigsaw - cheap and easy, but it will be loud :-)

tim replied:

I would get it cut at a metal fabrication place if you can.
They will use a guillotine and it will be cut straight and less hassles.
Cheaper than having to go and buy all the stuff req`d
Tim

Eric Experience. replied:

Scott.
A standard carpenters electric saw with the normal tunsten carbide blade is best. cuts clean and striaght and not very niosy, Eric.

thomo replied:

5" grinder and some alloy cutting discs pretty simple really.

Rosco - Bris. replied:

Scott

Eric's on the money. Standard wood working tools are OK for aluminium ... that includes chisels, planes etc.

May dull the blades but won't stuff them.

Happy chomping

Foss replied:

G'Day scotthomewood

The recommended machining/cutting lubricant for aluminium is kerosene. Bit of a bugger to clean up afterwards but leaves your material and tools in much better condition.
Carbide toothed cutting blades on circular saws will work fine.Safety glasses are a must, the swarf will come of in tiny slivers that are very sharp.

Grinding impliments are next to useless on nonferrous metals, unless they are very specialised which = expensive.

As stated above, woodworking type tools will work on aluminium. However, I wouldn't be using my best cabinet making tools !

For ease of use and versatility I would stick to the jigsaw. A course toothed blade, a good measure of patience and someone with a tin of kero and a small paintbrush to help you. Don't draw your cutting lines with a texta :-)

Good luck with the project.

Cheers
Foss

Fourth Ave. replied:

If you cut aluminium with a carpenters 9.5 inch saw have a friend that will spray oil on to the saw blade.If you cut the aluminium with out oil the blade gets hot
the aluminium sticks to the teeth witch makes them bigger and thats when you
can get a kick back, its ok if the saw misses you as it flies through the air. If your right handed and you are leaning over sheet of metal the saw blade is in line with your right leg. Use a fine tooth blade and protect your eyes and hands.
I have some experience in cutting metals and wood.
PS the blade should just go through the metal sheet.This gives you more control.
Clamp a straight on the sheet to guide thje saw.
You have to be in cntrol of the saw.
I am not a know all I am just very careful
Michael

Ian Bee replied:

One word.........

Guillotine.

Aside from the best cut, have you considered the noise you are going to make at home?

Member - Royce replied:

I cut 3mm aluminium checkerplate for my offroader. I used 4 1/2" angle grinder with standard cut off wheels. DON'T DO IT! Well you can... 'cos I did [noisy, messy and not very neat].... there has to be a better way. Probably measure twice and have the place you bought it from cut once! Cheers Royce

PETER replied:

I recently made my own aluminium canopy for my dual cab ute. I used a guillotine at a local steel supplier for all the straight cuts, used his sheet folder too which was great. For all the other cuts, nothching out corners etc, I used a 5" grinder with the thin Stainless cutting dics, worked well. For the windows I used a jig saw with a fine metal cuting blade. Make sure you use a quality jig saw that you can vary the cutting action so it is not to aggressive. I also cut some bits on the drop saw, using a fine tungsten blade and go very slowly so it doesn't bite in. I wouldn't like to cut it using a circular saw but if it works, why not. Make sure your cuts are neat as filing/sanding is diffcult. I used 2mm checker plate. Good luck.