How to Cut 24” aluminum squares - 1/4" aluminum
Purpose - boards for mounting various metal artwork on them
1. Bandsaw - excellent, but have to use a wood-cutting blade. Steel blade will cut too slowly and warp the metal at the cut. Go slow and follow your line as precisely as possible. Bandsaw will have the smallest kerf. Clean up the edge later with a grinder.
2. Table saw and hand-guide it - excellent method - use a thin sharp blade with 60+ teeth. Wax the blade on both sides before cutting. Go slow - wear face shield, apron, arm guards. The guard must be very secure and very square. Stand to the side and watch out for kick-back.
3. Scroll saw – will it cut aluminum that thick? - no
4. Electric hand rotary saw – will that have enough power? Yes - excellent choice. Use a straight guide, clamp it securely (not pony clamps - they will vibrate loose), wax the blade. Make sure that you have minimal blade extension.
5. Jig saw with a metal cutting blade – would that work? Not so well.
6. Sawzall? Can work, but not ideal.
7. Plasma cutter - cuts fine until the metal heats up, then it starts melting into the kerf. Try to cut under water.
8. Probably will have to end up with 23.5” x 23.5” Yes - you will loose the kerf
9. Get it laser cut or water-jet cut - waterjet cutting is ideal, though expensive and usually takes a lot of time (2 weeks is normal out here) plus driving time there and back. No to the laser, though I hear they can coat the aluminum first, then laser cut it.
10. Makita JS3200 - it will cut edges off of 1/8" aluminum but not 1/4".
Alternates
I could use wood for the base – baltic birch with routered corners? Painted black?
I could frame the weavings
How are the weaving & board going together?
Flame or color the weaving in some way
Seal it with Incralac.
Cut a piece of luaun that is a little smaller – poylcrylic both sides
Precut holes through both the luaun and aluminum
Dapple some glue or Liquid Nails on the back of the weaving - 3M 90 Spray adhesive works best.
Tape ¾” 1/4x20 flat-head screws to the glue side of the luaun and carefully lay it on the weaving
Fold the excess weaving around the luaun, then glue and staple in place
Use a spacer board between the luaun and the aluminum – baltic birch – this will need the holes drilled through it as well – edges should be sealed with black Deft polyurethane
Aluminum – will this be painted black? Polished aluminum? Wire brushed?
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