Cutting Techniques With A Table Saw...

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Hey guys,Here are some cutting methods I employ for sometimes unusual jobs or configurations. Because there are risks involved, I am not recommending anyone do this. I do this method because of the ease and time-saving it allows and is quite cost-effective at work. EXTREME CAUTION is advised if you attempt these methods. COMMON SENSE should be engaged 100%. I developed this method to slot square AL tube for the glass panels we make at work 7 years ago... NEVER one incident or accident......Photo 1: The blade guard must be removed to perform these operations. The photo shows a .250" slot in a piece of 1.5" sq. AL tube. The blade is a thin(.100) kerf ferrous 80 tooth blade. This blade is rated at 5800rpm and my saw is 5000rpm. Be sure to have proper blade for high rpm cutting.Photo 2: Fence is positioned .750 c/l to the blade.Photo 3: Blade height is positioned .150" to just clear the 1/8" wall  thickness.Photo 4: I spray the blade & inside of the tube with WD-40 & start the cut. WD will keep any AL buildup from the blade and give a clean cut on the material.Photo 4a: Complete cut---measured for c/l & next operation.There are 2 more posts with this one, 11 total photos, so please don't reply till all posts are completed. Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Photo 5: Fence is adjusted to a distance of .625" from the fence to the blade edge.Photo 6: After the first cut, rotate the tube to cut the other side....see arrow?Photo 7: The tube is rotated & other side is cut. This makes a .250" slot in a 1.5" piece of AL tubing. The slot can be made into any width and is determined by the distance of the blade to the fence. The closer to the fence, the larger the slot.Photo 8: (2) "C" channels easily made by cutting tube in half on each side.Photo 9: To make angles, set the fence so the blade is just inside the wall of the tube. After the first cut, turn the tube to cut the opposite corner.On to last photos & remarks..... Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Photo 10: After cutting, you will have a piece of 1.25" angle & a piece of 1.5" angle.Photo 11: Some of the configurations you can do with a simple table saw.PLEASE!!!!! If you attempt to try to do this type of cutting, be very aware of your methods, physical protection, and just simply pay attention to what you are doing. Carelessness can be quite painful and debilitating. Hope some of you find these methods useful.....Good luck.....Denny Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:I -think- you meant to say you used a thin-kerf NON-ferrous 80 tooth carbide tipped blade.  Like a Freud Diablo D1080N thin-kerf (0.098 inch kerf) 10 inch diameter 80 tooth carbide non-ferrous blade. (yes, I generally like Freud blades.  No, I don't work for them.)Yup, a table saw with the PROPER blade can cut aluminum or other soft non-ferrous metals (copper, brass, don't try to cut titanium that way  )
Reply:You can cut steel if you had a steel cutting blade, but check the speed of your saw, most are to fast, also the metal filings are not good for "wood" saws that are expecting nice soft saw dust.  One recommendation:use feather boards to hold the work in the proper place during cutting this allows you to keep you hands away from the blade, and also makes it so the material does not bind (bad, very bad).