Cutting aluminum

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Forum topic by quartrsawn posted 892 days ago 1379 views 0 times favorited 8 replies Add to Favorites Watch
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143 posts in 1839 days

892 days ago

Topic tags/keywords: question miter saw blade milling aluminum cutting

I need to trim an aluminum threshhold/saddle. Can this be done safely on a 10 in. miter saw with a 60 tooth carbide blade? It is 5” wide x 3/32 thick. Thanx

-- Nat - West Sayville,L.I., NY

8 replies so far

View oluf's profile


256 posts in 1665 days

#1 posted 892 days ago

Yes. Just ware a face mask. The chips are hot and they are sharp.

-- Nils, So. Central MI. Wood is honest.Take the effort to understand what it has to tell you before you try to change it.

View GerryB's profile


44 posts in 1208 days

#2 posted 892 days ago

How about a hacksaaw?

-- The pursuit of excellence is gratifying and healthy. The pursuit of perfection is frustrating, neurotic, and a terrible waste of time. Edwin Bliss

View Viktor's profile


447 posts in 2045 days

#3 posted 892 days ago

Yes. I cut aluminum extrusions and angles. Normally you would need a specialty blade with different teeth angle, but for smaller peaces regular 60-t blade will do. Spray some DW40 on it for cooling and lubrication, although for a piece this small it does not matter much. Clamp well. And yes, chips get hot.

View BlankMan's profile


1487 posts in 1979 days

#4 posted 892 days ago

I’ve got a couple of 10” blades made especially for aluminum. They’re HHS not carbide and have way more teeth, I’d guess at least 80 maybe more, and a very shallow gullet. They weren’t expensive either, don’t remember what I paid but I wouldn’t have bought them if the were. Picked them up at Menards and I think they were Oldham. Don’t know if they carry them anymore or if they’re even made anymore. Someone told me a trick one time when cutting aluminum and that was to put the blade on backwards. Sounds stupid and I’m not suggesting or endorsing it but I have done it when cutting really thin aluminum and did get a smoother cut. Don’t know if that’s really good for the blade though, I wasn’t real worried about it as I don’t cut a lot of aluminum with a circular blade anymore, I use a bandsaw.

-- -Curt, Milwaukee, WI

View NiteWalker's profile


2709 posts in 1203 days

#5 posted 892 days ago

Never cut anything with the blade on your saw backwards. All it does is causes stress on the blade tip joint.
It doesn’t improve the quality of cut at all. I see this recommended a lot for cutting plexiglass on the tablesaw even though a 40 tooth general purpose blade works just fine.


-- He who dies with the most tools... dies with the emptiest wallet.

View Paul Stoops's profile

Paul Stoops

322 posts in 1187 days

#6 posted 891 days ago

Yes, I am working on a project that required cutting aluminum extrusions and 1/4” plate. I bought a 100T Oshlun blade designed for cutting aluminum which worked superbly. I also bought a cheap face shield, which helped a lot to keep the chips out of my face.

As previously stated, your 60T blade will work okay. Spraying the blade with WD-40 before cutting helps, as well.

-- Paul, Auburn, WA

View quartrsawn's profile


143 posts in 1839 days

#7 posted 891 days ago

Thanx for all the info and insights. I too never liked the idea of running a blade backwards.I have done this before with a Jigsaw and a metal cutting blade. Hot fliing metal chips may be an issue at the jobsite (retail store). Even with the jig saw I’ll use WD-40, can’t hurt.

-- Nat - West Sayville,L.I., NY

View BobM001's profile


388 posts in 956 days

#8 posted 891 days ago

A “triple chip” carbide is the preferred blade for cutting non ferrous metals. Get a tube of stick wax and cut into it with the saw running. Just enough to coat the tips will do the trick.

-- OK, who's the wise guy that shrunk the plywood?

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