Scroll-Ban-Saw Table cutting question - Aluminum
 

I'm looking for an easy way to cut 1"x1/6" aluminum strip bar.

I have this old scroll table saw sitting in my basement, never used it. My father-in-law picked it cheap at a garage sale a couple of years ago and I ended up with it.

I don't want to ruin it, nor ruin myself using a blade and a saw not intended to cut aluminum.

I was hoping to clamp a wood stop block 2-3/4" away from the blade and cut 200 pieces of 1/16" thick x 1" wide aluminum bar. I then need to drill a hole near one end and don't have a drill press either.

I don't want a lot of burr cleaning and grinding of edges to do afterwards.

Can this saw (and blade) handle it?

If not, what then should I be using?

I'm not going to hack saw 200 tiny pieces although I could use the exercise.

MISC pictures by kach22i - Photobucket
http://i184.photobucket.com/albums/x.../MISC/saw1.jpg
http://i184.photobucket.com/albums/x.../MISC/saw2.jpg
http://i184.photobucket.com/albums/x.../MISC/saw3.jpg
http://i184.photobucket.com/albums/x.../MISC/saw4.jpg

http://i184.photobucket.com/albums/x.../MISC/saw5.jpg

I do have a contraption which turns any circular saw into a make-shift table saw. I've used it before, it's not bad on some rough stuff. Never tried to cut metal with it though.

I've been cutting aluminum flat bars, angles and things with my 4" grinder for years, there has got to be a better way.

I doubt you'll get a consistent square cut with that. I'd get a $50 miter saw off Craigslist and put a metal cutting blade on it. That will be way easier and more consistent.

You may have to deburr, but that can be a very short operation with a sander.

I also have a bench mountable grinder/buffer which came by me the same way.

Miter saw, also called a chop saw, right?

It will do it, but it won't be a particularly nice cut....

You really need a sheer for that.......

If you're going to do this often, you might prefer a new one saw. This one is only $115 on Amazon.
http://ecx.images-amazon.com/images/...500_AA300_.jpg

Get yourself a good aluminum cutting blade too. $44 on Amazon.
http://ecx.images-amazon.com/images/...500_AA300_.jpg

Both of these get good reviews.

Layout your cuts and holes. Drill the holes first being able to hold on to the long stock (within reason, you might want to cut some 4' strips first). You will probably want a DP for this, but's not necessary. You can get a reaming tools to dress the holes.

AFA as the scroll saw, forget it. Not impossible, but it's not the correct tool; not even close. A chop saw will be somewhat dicey, but it will work. Watch out for the blade picking up the stock. You should use a hold down. Still, a few of the cutoffs may fly.

A band saw is the perfect tool. A table saw could be used with the same cautions. Aluminum responds well to high speed cutting. The key is to hold it down well.

Thanks everyone, I'm getting a better feel for the problem and the task at hand.

This should do the trick:

http://forums.pelicanparts.com/uploa...1331842017.jpg

You maybe able to rent what you need at your local Homedepot.
+1 with the chopsaw and the correct blade just cut through slow and steady. P.S where a Face shield.

A carbide blade on a table / circular saw will be fine. I wasn't clear if you had 200 of those to cut? If so, use something with power. If it is one? Use a hack saw and file it smooth.

I take it this is for 911 training wheels 2.0?

I don't know.

It's right behind you, on the left. Below the hearing protection.