best way to cut 1/8" aluminum sheet metal

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I would like to fabricate end tanks for a custom made intercooler setup.  I plan on fabricating the end tanks out of 1/8" aluminum sheet metal but I was wondering if I could get recommendations on the best way to cut it.  I thought the best way would be with a vertical metal bandsaw but the only models I can find are of industrial grade and way too much $$$ for me.Thanks in advance for any suggestions or recommendations.
Reply:many people use table saws to cut sheet aluminum, but I'm not sure about 1/8 inch thickness.  Sounds risky.  How about taking the sheet to a shop with a large break?
Reply:Originally Posted by HokieEdmany people use table saws to cut sheet aluminum, but I'm not sure about 1/8 inch thickness.  Sounds risky.  How about taking the sheet to a shop with a large break?
Reply:I always have mine sheared.  It's the only way I have found that causes the least amount of cosmetic damage to Aluminum.  Shearing also leaves a nice edge for welding.  If you could use thinner (.065?) Aluminum for your project,  those handheld electric shears work nice.
Reply:Originally Posted by x1riderWhat is you guys' opinion on this band saw here, it seems like it can be both vertical and horizontal.http://www.northerntool.com/webapp/w...3677_200323677Thanks for the input.
Reply:For one off cuts in thickish aluminum I like to use the "Bullet" carbide blades in my skill saw.  They make a nice clean, straight cut.
Reply:Plasma is how I cut mine.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:Airwolf:  can you cut a .125 thick sheet of AL with the skill saw?
Reply:Originally Posted by Hammack_WeldingPlasma is how I cut mine.
Reply:Originally Posted by HokieEdAirwolf:  can you cut a .125 thick sheet of AL with the skill saw?
Reply:Originally Posted by HokieEdAirwolf:  can you cut a .125 thick sheet of AL with the skill saw?
Reply:X1Rider,1/8" aluminum plate can be easily cut with a horiz or vert. bandsaw, with a skilsaw, or with plasma.I use a cheap ($40 Skil--Lowes) 7 1/4" skilsaw with a 24T carbide blade.  A little beeswax seems to help prevent galling of the teeth.  Morse (Metal Devil) also makes a blade specifically for aluminum.  I've cut aluminum plate up to 3/8" with this setup.For small pieces, a bandsaw works well.For 1/8" material a jigsaw will do a nice job for you on smaller pieces.There has been considerable discussion over on the Miller board regarding cutting aluminum with plasma.  Several have found that the edge still needs to be ground to prevent contamination induced by the plasma.  Have not experienced it myself, but seems that the concensus is to grind the edge after the cut.For thinner aluminum, I will generally sandwich the material between two pieces of 3/8" plywood.  Keeps the edges square.  I've done this numerous time when cutting sheet on the table saw.Hope this gives you some options.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Nearly every weekend, I cut 1/8" & 1/4" aluminum using a regular table saw and/or a chop saw, both set up with a fine tooth carbide tipped blade.For the table saw, think it through before to make the cut.    Where are you going to stand?   If the material kicks back, will it hit you?    If you're trimming an edge, can the small cut off section fall between the spinning blade and the saw table?   If so, use a piece of scrap plywood to reduce the gap around the blade.Cut slowly and use featherboards to hold the material to the table saw surface.MOST IMPORTANT, wear eye, or better yet, full face protection.Some cutting fluid on the chop saw blade improved the look of the cut.There are no small projects
Reply:thanks to everyone for the input, it is much appreciated!
Reply:yeah, I learned a good deal too.  thanks.
Reply:It will cut very easily with a jig saw and a wood cutting blade.  I will sometimes spray a little WD40 along the cutline which seems to make things go smoother.
Reply:Originally Posted by fatfrankIt will cut very easily with a jig saw and a wood cutting blade.  I will sometimes spray a little WD40 along the cutline which seems to make things go smoother.
Reply:Not mentioned is the router.  If you have to make a lot of parts, make a template and route it.  Use plenty of oil or it will gaul the cutter.
Reply:Shear is the best but Plasma runs a tight secondLast edited by jamlit; 09-01-2007 at 06:42 AM.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:A skilsaw with a non-ferrous cutting blade. Usually a 40 tooth carbide blade, made for metal cutting. No oil, clean clean cuts, and you can cut way faster than with any other tool for that job. The blades are sometimes available at Home depot, etc. Usually I get them at my hardwood lumber shop/ Ganahl lumber out here. They are about $50 ea. and last about a year when you cut aluminum with them.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:A bandsaw with a wood blade works fine.  The alum does no damage to the blade.  I use a small leg to support the alum at the blade (hard to explain-its an L shape clamped to the table with a groove for the blade to pass.)  This leg only contacts the sheet about 1/4" wide so surface is not damaged by the talbe and parts can be easily swiveled around for tight circles.A jigsaw mounted upside down in a table also works fine with a wood blade. (a cheaper option if you only need a few parts.)