How're you guys cutting your aluminum sheets?

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Hey, just a quick semi-noobish late night question for y'all...What is, in your opinion, the finest way to cut sheets of aluminum? I ask because I've been using my 8" Metal Cutting Circular saw for quite some time, and its been great... Only thing is that the blade is now dull, and it mangles the aluminum, which leads to epic contamination when i try to weld it. I'll just pick up another blade, and have this one sent somewhere to be sharpened I guess...But it got me thinking... What's YOUR preferred method? [Account Abandoned 8/8/16 Please Do Not Attempt Contact Or Expect A Reply]. See you on YouTube! -ChuckE2009
Reply:Table saw with a carbide blade.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:I use a 7 1/4 inch blade in my circular saw.  I buy the cheap 32 tooth carbides.  I set the saw depth to about 1/4 or less sticking out below and use saw wax.
Reply:Wonder board and a skil-saw. Normal wood cutting carbide blade. The wonder board protects the finish of the aluminum. If your doing a large layout a sheet of pink foam makes a great sacrificial board.http://weldingweb.com/vbb/showthread.php...31#post3305131I also use my table saw. For inside areas I use a router or a jig saw. I use my plate saw on occasion but tend to prefer my worm drive skil saw on aluminum.Last edited by forhire; 10-03-2014 at 11:43 PM.
Reply:I use either my 6ft x 10ga Edwards power shear or my 4x8 CNC Plasma table with a Hypertherm 65. Here's some 1/2" aluminum cut on my plasma tableSome .090" aluminum for a custom signand some .050" aluminum door skinshttp://all-a-cart.comWelding Cart Kits and accessories
Reply:CNC for me.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:I've started using a double cut saw. It cuts through it fast.Harder to keep it straight compared to circular saw with a guide.MillerMatic 212, Lincoln Precision TIG 225, Hypertherm 45XP
Reply:i use a regular saw with a alu blade and cnc rotor table lennox or acculube make the best saw wax.  p.s. sure hope your not quoteing the guy from red jacket in your sig lineHigh Octane Welding
Reply:Your equipment list shows a Powermax 45. I generally use a plasma to cut sheet. Straight cuts I use a know straight edge clamped to the sheet as a guide. Just make sure you figure in the extra to clean the plasma slag.
Reply:If using a plasma to cut aluminum, spraying the bottom of the cut with anti spatter spray helps keep the dross from sticking. I usually use a circle saw with a carbide tip framing blade with the sheet laying on foam board, just cut slightly into the foam. A jigsaw with a fairly coarse blade works well also when using some wax on the blade and cutting on 2 inch foam board.
Reply:Rigid worm drive. I use a Diablo aluminum blade. As they get dull, they heat and get more dull, then they pick up a build up of aluminum on the face of the tooth. It's hard to find, I've used substitutes, but a light coat of Butcher's Wax on the cutting face of the teeth helps with build up.Keep up the good work!
Reply:I use a regular fine tooth (wood) blade, I put it on backwards.-c-
Reply:ZTFabs you are just showing off all that nice equipment !! But I use  Slugger saw , sabre saw on pink board and plasma , don't have any of that new fangled CNC thing a ma bobs .gxbxc
Reply:Originally Posted by gxbxcZTFabs you are just showing off all that nice equipment !! But I use  Slugger saw , sabre saw on pink board and plasma , don't have any of that new fangled CNC thing a ma bobs .gxbxc
Reply:Table saw, skil saw, jig saw, wood cutting chop saw, air die grinder with wood cutting blade.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:I use a freaking grinder and a walter zip alu.... damn i feel crude lol
Reply:I have one of theseGlenMiller Dynasty 200DX - Millermatic 350P - Hypertherm Powermax 45Want to sell!! - Hobart Handler 150
Reply:Before I had a cnc and plasma I used a bandsaw. The harbor freight portaband and I built a stand for it. It worked GREAT except for how loud it was. If i had to do it again I would get a better name brand saw and a swag off road table.Chucke that's a good idea for you, get a old bandsaw and convert it to run at a lower speed for steel and aluminum.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:You need a really big band saw to saw 4'x8' into two 4'x4' .
Reply:I guess I am the ONLY one to use a track saw?!? grizlly, fox, shop schlepepe all make them cheap for under $200, Makita, dewalt festool, etc make the expensive variable speed ones. I'm surprsied as it is by far the most versatile thing I have ever cut aluminum sheet with.we also use wood chop saw, jig saw, angle grinder with appropraite blade in it.I just picked up a makita variable sped one and I will try cutting 1018 steel plate soon with it.
Reply:The Festool track saw has revolutionized my shop. On aluminum I also use Skilsaws, table saws and band saws with fine pitch carbide blades; for special cuts, a saber saw or Sawzall. Wax lube helps keep the blade from clogging.
Reply:Originally Posted by AluminumWelderI guess I am the ONLY one to use a track saw?!?