Best method/tool to cut aluminum sheet

[Rick Dorion]

I'm having trouble cutting .060 aluminum without distorting the edges. I want to make engine compartment panels. Appreciate and insights and recommendations! Thanks.

[Matt@RFR]

Jigsaw with coarse wood blade, skillsaw with wood blade, table saw with wood blade, router with single flute cutter, plasma cutter.

Just don't use any abrasives to cut aluminum.

[Rick Dorion]

Thanks. I'm using 6061-0 which seems very soft. Should I use T4 or T6 (or a different alloy)?

[Matt@RFR]

May I ask why you're using a zero temper? If you have to bend the stuff, 5052 or 3003 would be better, and you could use those in their half-hard state (H32) and still bend it easily, and both will work harden when you bend them.

[Rick Dorion]

Ignorance, that's all. Went to the Aircraft Spruce catalog and ordered I'll look at these. Thanks, Matt.

What other suppliers are available? really need some guideance on what to buy and where. Thanks again.

[Matt@RFR]

Well, before you go ordering all kinds of sheet, the 5052 and 3003 are just alternatives. The 6061 T0 you have will work fine. Be aware, too, that if you mix alloys and you leave your panels unfinished (natural), they will look different.

The only other online suppliers I use for metals is www.onlinemetals.com and McMaster-Carr. I don't have time right now to go look, but I think both of them carry sheet.

Really, your best bet is a local metal supplier if you have one. Shipping sheet gets expensive.

[parsonsj]

5052-H32 is what I used for nearly all my sheet aluminum. It cuts nicely with a bandsaw or a jigsaw.

jp

[Rick Dorion]

What thickness, John? Thanks.

[Matt@RFR]

I don't know what John used, but if these are just panels with no structural job at all, .032" works well.

[parsonsj]

All my aluminum stuff is .060. A bit thin for welding (tends to warp), but seems just right for inner fenderwells, radiator core supports, etc.

jp