Cutting Aluminium

[carmangary]

If you use a jigsaw I recommend clamping something like a piece of angle iron or wood to it to use as a guide. Just keep your jigsaw pushed up against the guide as you cut and you'll have a nice straight line.

[Pitts]

Had to do a lot of ali cutting while building my aeroplane.

I have used the jigsaw way a lot and not had any issues at all.

To save the ali from vibration marks from the jigsaw I use wide masking tape... you can then also draw on this very easily with a felt tip pen.

As suggested above make sure you use a guide rail of some kind or it will look like a drunk drivers path.

Strangely enough ali' responds better to a 'coarse' blade and the same is true for any initial filing, Use a heavy cutting style file until you are ready to finish it off.

Lubricants work well with ali' specially when drilling and tapping for threads.

Cheers

Ray
NZ

[DZ]

I've had tons of luck cutting with a table saw. I purchased just a regular table saw from Home Depot a few years ago, and bought a blade specifically for cutting non-ferrous metals. I get nice, straight clean cuts. Even used it to cut the top 1/4 inch off of a replacement Lasever blue laser last year, and its still working!

[Dr Laser]

Build a prototype case out of card board. Locate where all you elements will be. Take it apart..measure all parts and bring it to local metal shop. It should not be more expensive then 200$. Including aluminum and cutting and punching holes for fans and etc..

[dave]

For cutting extrusion and the like, we have a drop saw with a aluminum blade.. Does a great job

[carmangary]

Lubricants work well with ali' specially when drilling and tapping for threads.

Kerosene works well for that.

[mixedgas]

Kerosene works well for that.

So does tapmagic in small doses

Steve

[laserLips]

Wooa lots of info. Thanks.
Many types of saw I've never heard of. I'll have ago with the Jigsaw. Like the guide rail idea but I wont be able to pin the guid on.
I'll just use masking tape.
If it all goes to pot I'll order some pre-cut stuff from ebay. Theres a lot on there at the moment.

[helium]

A set of cheap G-clamps will hold the guide rail in place.

[Banthai]

mixedgas said

So does tapmagic in small doses

Steve... thats something you dont see a lot of over here in the UK

but i have to say.... when i was working in chicago ... i was introduced to it ..... its one of the best cutting compounds i have come across and i even brought a large bottle back in my suitcase everyone who has used mine recons its mega ....

all the best ... Karl