Have you guys ever cut 1/2" aluminum plate with a chop saw?

It takes 90 years with my band saw to make long cuts.

I need to make another one of these

- Joe

 

I usually use a circular saw with a carbide blade or just a jigsaw with a course blade.

 

6 tpi bandsaw blade would work nicely

 

..and some candle wax.

 

Since it is the blade that is actually doing the cutting, don't cheap out and buy quality blades.
Whenever I have to make something like that, I use a 1/8" drill bit to drill a series of holes along the line I need to cut. Then use the jig saw to connect the dots. Smooth it out with a sander.

 

Sounds like you need a different blade for your band saw. I just have a porta band on a stand and it eats through anything even on the mid speed settings, I have a course tooth band in there. If I crank up the speed, it is almost uncontrollable how fast it removes material.

 

Thank you guys.

I'm using a 18 tooth per inch blade on my band saw, which is what I use for steel. I'll give a 6tpi blade a try, and perhaps some candle wax.

Thank you again for the suggestions!

-- Joe

 

The master builder in the fab shop (I sort of helped manage) swore by his reciprocating saw and an "axe" blade for cutting thick aluminium.

https://www.milwaukeetool.ca/accesso...ing/48-00-5021

5 TPI and the wax to keep it from loading up. I wouldn't have believed it if I hadn't watched it with my own eyes.
My guess is that 6 TPI in your band saw will give similar results.

 

Soooo..

To do large cuts, I used the chop saw with a dimensional lumber blade. Cut like butter.

For the curved cuts, I used the band saw. Took a while, but the most coarse blade I could find was 10 tpi.

Aluminum is weird.

-- Joe

 

I use trans fluid to help keep the blades from loading up. A little messy but it works.

 

I guess I'm spoiled. I just use a cnc miller. but I do agree with the low tooth count for the saw blade.

 

The supplier that milwaukee uses for their bandsaw is ridiculously good for how much they cost. I need to find out who makes them so I can buy the same for my fullsize bandsaw. I've been using the Olsen brand and haven't been impressed. I'll be trying Lenox next. A 14 TPI blade on that portaband is like a hot knife in butter for 3/16" and under.

 

I use Lenox bandsaw blades at work for steel and they're great. I believe I ordered the Lenox classic blades. Hold up very well.

 

I have a Dewalt portaband, but I bought the Milwaukee bands too.