Q: Cutting 1/2" to 1" aluminum stock to make barrel bands?

[toine]

I have access to mostly basic woodworking tools, and I was wondering if anyone had advice on how to cut aluminum stock in the 1/2" to 1" thickness range such that I could make parts for a bullpup project I've been putting off since last year. Initially I had hoped to have access to a hackerspace with a full metal shop, however it is not currently in the cards. Is this something I could get away with using a miter saw?

Any advice would be most welcome.

[Big Bore Bart]

    If you can clamp it up, it'll work.   I've been cutting 2 x3" solid 6061 on my table-saw lately for another non-AG project.   Homers has a Diablo saw blade for non-ferrous metals, it's what I'm using.    The blade is for table-saws or miter saws.  I have used ordinary carbide blades as well.

[SeanMP]

You can absolutely work aluminum with wood working tools.

I spent some years as a project engineer at a shipyard that specializes in aluminum boats/ships. All of the tools they used were wood working and carpentry tools. The tool of the trade is the common skil saw, but they ripped strips on table saws, edge prepped plates for welding with routers, cut extrusion with chop saws...etc

The blades in the big equipment were high tooth count carbide but the blade of choice for the skil saw was the cheap HSS version. High tooth count like paneling blades.

[Roadworthy]

Tony - just a bit of added info.  Check Harbor Freight.  They have reasonable prices on high tooth count carbide tipped blades.  Beware, when you're cutting the kerf seems to be a bit wider with carbide tips.

[GarthThomas]

I would use cutting paste on the blade first or even some kind of penetrating oil to keep it from clogging the teeth and grabbing. Be careful, I know several guys who have relieved themselves of digits cutting aluminum in particular.

[Bill G]

Yep.  I have cut 1-1/4 thick Al plate with a common circular saw.  I used a high tooth count carbide blade as wel las a HSS blade.  I have found that drawing a line of Tapmatic cuting fluid over your scribe line works great at allowing the blade to discard the chips well and hold heat at bay.   

[Bill G]

Oh yea, I'd add this to required PPE.  Face shield and hearing protection. Circular saw on wood is loud but on Al, really loud. 

[Scrambler82]

Not sure if you have cut the aluminum yet but use Automatic Transmission Fluid for lubrication, works great for cutting and drilling. 
Eliminate any aluminum build up on the cutting tool.

[ezman604]

Bees wax is recommended to lube cutting blades. I cut aluminum stock on a 14" bandsaw with a 6tpi all metal blade. You can also get good scroll saw blades to cut it. Jigsaw would be a rough cut but works. Nothing that a good belt sander won't fix up.

[QVTom]

At least no one suggested kerosene as a cutting fluid   The best lube is Retlon A9, the stuff in the green can.  It's cheap, safe, thick enough to stay in place and cleans up easily.  In 30 years, I've found nothing better.

Also be careful of kickback when using a circular or table saw when cutting Al. plate, you wouldn't want to loose your manhood!

Tom

[deweytastic]

good old hacksaw and elbow grease will do the job.

[Scrambler82]

good old hacksaw and elbow grease will do the job.

Only problem is without AT Fluid or other lube the aluminum will stick to the blade and clog the teeth.

[Bullit]

If you have any buddies in the electrical trade, or have a shop close to you, they can do it quickly for you.   If they don't have a Cutoff Band saw set up, they can just Clamp it up and cut it up, with a Port-a-Band.

[Scrambler82]

Was thinking about how to cut aluminum with a Cut Off Saw.   

What if...  You attach the aluminum bar to a piece of wood.
Maybe drill some holes in the barrel mounting area and mount with screws.
Cut very slowly, use a clamp if available to keep the hands out of the way.

Just what I would do to get it done and dependent on the width of the pieces.

If the Barrel Hole is equal to the Gamo BC I might want to buy a thinner mount from you... Or maybe one without a hole in it.

Ltr

[Scrambler82]

Was thinking about how to cut aluminum with a Cut Off Saw.   

What if...  You attach the aluminum bar to a piece of wood.
Maybe drill some holes in the barrel mounting area and mount with screws.
Cut very slowly, use a clamp if available to keep the hands out of the way.

Just what I would do to get it done and dependent on the width of the pieces.

If the Barrel Hole is equal to the Gamo BC I might want to buy a thinner mount from you... Or maybe one without a hole in it.

Ltr

[nmair]

Oshlun has saw blades specifically for aluminum that are rated for higher rpms- might be worth a look.