So I have to cut a shape into a piece of aluminum...

[FullyLitLED]

Say I had this piece of metal(picture is a random image from google), and I wanted to cut out the shape in red but have the edges more rounded, what power tool do I need to buy? Specifically, I need to cut this shape into a 1/8" thick piece of aluminum! Will a dremel be good enough? Or is there some kind of slectric saw that I could buy? A harbor freight just opened 10 miles from me so if you can show me links on the HF website, it would be helpful

 

[hedgehog23]

How tall is the slot you wish to cut in that aluminum? For the corners you can drill them with the drill press with the "correct" size drill to give you the radius you want. for the strait runs you can use a hacksaw or jigsaw

 

[FullyLitLED]

How tall is the slot you wish to cut in that aluminum? For the corners you can drill them with the drill press with the "correct" size drill to give you the radius you want. for the strait runs you can use a hacksaw or jigsaw

Good suggestion! I think I will buy a hacksaw or one of those cool rotary saws at HF

 

[scottm]

A waterjet place could do it for about $30, along with any other holes or outside edges or features you want cut. Tell me what dimensions and I can draw up a CAD file they can cut from. But buying new tools and doing stuff yourself is always my preference.

 

[crushers]

waterjet X2

i have been using the services of a local fabrication shop and the work is beautiful and cheap to boot.

other wise as suggested, hole saw, jig saw and sand. done.

 

[scottm]

Lasercut would also work for aluminum this thin. The shop I use doesn't like to go any thicker with aluminum.

 

[craptabulous]

you could do it with a jig saw or angle grinder .

 

[BirfMark]

Angle grinder with a cut off wheel for aluminum, as well as a flapper wheel to round the corners.


Or an axe, depending on your tolerances.

 

[BattleWagon]

Or an axe, depending on your tolerances.

lol...

 

[rusty_tlc]

As suggested above drill the corners use the implement of your choice, jig saw cut off tool etc., for the straight cuts.
Cut inside the finished size then FTF (file to fit). A bastard file will remove a lot of 1/8" aluminum fast, a mill file will smooth the finish.
Keep a wire brush handy to clean the files up.

 

[kiwidog]

Cutting aluminum

A jig saw works good. If you use a blade that is 1/8 '' deep you can cut corners no problem getting around 1/4 radius corners. Just spray the cut line with WD40. You can cut right to the line if you take it easy. If you wear glasses get a cheater pair and it will magnify the scribe line and make it easier to follow the line.
If you are cutting a sheet where you don't have to enter a blind hole then a wood cutting band saw cuts aluminum like butter. !/4" blade with 6 to 8 TPI will work. 6TPI is better. If you cut to the line then filing is a minimum. The glass really make a difference if have older eyes. Don't need WD40 when cutting with band saw however you will wonder at the difference it makes with a jigsaw.

Thanks jb

 

[spressomon]

A good friend brought his Makita 5-3/8" 18V metal circular saw over so I could cut a piece of 1/4" 6061. Damn...I hate when I "need" to buy another tool .

Yep...it worked that good!

Makita USA - Tool Details - BCS550

 

[PadgettFabrication]

find a buddy with a Plasma cutter. I can't believe no one mentioned a plasma cutter..... lol. good luck with your project

 

[walken100]

Oh i'm going to get flammed for this but variable speed router and a template following bit (carbide). Done lots in the hot boat world.

 

[FullyLitLED]

This?

5" DoubleCut Saw

 

[SM Racing]

Sawzall, Jig Saw, Router, Mill, drill, cut off wheel, metal cutting circular saw, plasma cutter, oxy acetylene torch, laser cutter, water jet, band saw, air chisel, nibbler, air shears, stomp shear, etc.

There are about a million different ways to cut it. In your case, buying a tool at HF to do one job seems really counter productive, unless you are trying to build a collection of worthless tools. In this case call up a fab shop and have them knock it out for you. Let them choose the best method. If I were cutting it, I would either use my bandsaw, plasma cutter, or sawzall with a guide. But that is just me.