Cutting aluminum

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Forum topic by quartrsawn posted 03-13-2012 02:16 AM 1863 views 0 times favorited 8 replies Add to Favorites Watch
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146 posts in 3235 days

03-13-2012 02:16 AM

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


260 posts in 3061 days

#1 posted 03-13-2012 02:18 AM

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


69 posts in 2604 days

#2 posted 03-13-2012 02:39 AM

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


464 posts in 3441 days

#3 posted 03-13-2012 03:02 AM

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


1490 posts in 3375 days

#4 posted 03-13-2012 03:26 AM

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

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2737 posts in 2599 days

#5 posted 03-13-2012 03:38 AM

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.

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Paul Stoops

348 posts in 2583 days

#6 posted 03-14-2012 12:41 AM

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


146 posts in 3235 days

#7 posted 03-14-2012 01:33 AM

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 2353 days

#8 posted 03-14-2012 02:16 AM

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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