Cutting Aluminum

[willy]

Hey guys moving right along with spring opening, installed new LED nav lights on bow, installed new Lowrance 3500C and new horn and dressed up some wiring under the dash.
I had a problem last year if you remember where my engine sits about two-three inches to high on the bracket and ventilates when I try to trim up or go to fast in a chop. I spoke with Armstrong today and I can lower it and drill new mounting holes no problem but the top edge of the riser plate on the back of the bracket needs to be cut down about 1.5 inches, also no problem they say. How would you cut half inch thick marine aluminum, with a 90 degree turn at each end. I have a good sawzall and can get a couple of good metal blades but I am worried about being able to keep a straight line that way. Any suggestions

[chumbucket]

Make up a jig to be bolted or clamped horizontally at the given height that you need to make the cut. Just use that as your straight edge.

[willy]

I was going to do that but there realy isn't anything to clamp to there, and the bolt holes are where i need to cut. Have you ever used a sawzall to cut thick metal like that CB

[pikfish]

I worked at a machine shop a few years back and they would use a skill saw to cut thick alum. 4' x 8' sheets down to size. I thought that it was crazy be after seeing how well it worked I have done it myself with good results. I used a carbide tip blade, I agree use a guide and a slow feed rate.

[Vic]

Willy, You can get metal cutting blades for a skilsaw to do it but I would set the saw to just score it first and grind off a little deeper each pass so you dont get your blade in a bind. Buy a couple of blades, just in case they grind down pretty quick. Hope this helps.

[macojoe]

Use a long Bar clamp from wood working, that will go across the top and down the sides for the clamp.

Skillsaw all the way!!

[willy]

OK I was wondering if a circular saw (that is what you mean by a skilsaw right?) would work better than a sawzall. Looks like I need to go blade shopping thanks guys ;)

[chumbucket]

Circular saw works well. Wear some good hearing protection. :o

[Franco]

HEY WILLY, DO YOU HAVE A ROUTER - YOU CAN BUY ROUTER BITS MADE TO CUT NON FERROUS METAL. GET A PIECE OF PLYWOOD AND BOLT IT TO THE BRACKET TO USE IT AS A STRAIGHTEDGE GUIDE AND GO SLOW - OR YOU CAN DO THE SAME THING WITH A JIGSAW, JUST LEAVE A LITTLE AND GRIND IT OFF.

[Mac_Attack]

Use a router and a router table. Less clean up of the cut. Bill McIntyre ;D

Hearing and eye protection required!

[Vic]

Yep Circular saw. You guys are brave with those routers and alluminum whew! I could just see it flying. I'm too chicken for that.

[phester]

willy, don't use a sawzall, it'll be difficult to control. I'm not completely sure what has to be done ,but, I think a straight edge an a good jig saw[ one that prefferably has reciprocating settings].....eye protection, slow and steady you should have no worries

[willy]

Thanks guys for the advise ;D Believe I will try to make some kind of straight edge and use a circular saw with the right blade, the little sears jig saw I have is not up to that kind of job

[reelapeelin]

Willy, just keep in mind, if that circular saw gets sideways in the cut it'll KICK-BACK like you never seen :o...don't set the blade ANY deeper than the materail...and go slow...

I have a HEAVY DUTY jig-saw that I'll ship to you...more control and LOTS safer...holdin' that circ-saw up sideways to make that cut's gonna be a BEEYUTCH!!... :P :P...lemme send you this saw... ;)...

[willy]

Thanks Oz for the offer I will check with a few well endowed friends of mine ( mechanical tool wise Stinky don't worry) and get it up here, but thank you for the offer, much appreciated :)

[chitbob1]

been cutting aluminum for a week now circular saw all the way I just put a lowrance 3500 c in my boat also external ent.

[willy]

Same with me, mounted the external too. Now I will be able to find myself like Rap ;D

[willy]

Well guys thanks for all the info, used a combo of circular saw with a cutoff type blade to score the 1/2 " aluminum deep and a sawzall with a metal blade and it worked well. Ground down smooth and painted with white industrial spray paint to cover bare metal. Because of taking off the metal I was able to lower the motor 2 3/4" , should be enough to keep the prop down in a good chop now.
Got new GPS installed with external antenna, new LED Nav lights on bow and new horn installed. As soon as the bracket gets here I will install my Suzuki 9.9 kicker motor and then its off to the happy fisheen grounds for Willy ;D

[willy]

Franco buddy, when you coming up I'm almost ready for you man, we go catch some stripers, some flounder and do some drinking and silly acting.

[Franco]

Hey Willy, bring her on down the ICW when you move here from Joisey! I just found out that there had been a job open for a Police Chief in Fellsmere, they only have 6 or 7 guys on the whole force!!! They ended up hiring the lieutenant from the force for the job. Sorry, I wish I would have know about it sooner!

[willy]

Thats all right Bud thanks for thinking about me, see all the work I'm getting done for you man, you still coming this way this summer

[Franco]

Wow, you must have read my mind!! I was being a smart$$ to you and your message popped up before I posted mine! We may sneak up that way in july, gonna be tight, breaking up my vacation time to go 2 places.

[willy]

Yea but you will miss me :o

[reelapeelin]

Hey Franco...if you need a half-way place to crash I'm here for ya!! You know you can for as long as you need, Bro... ;) 8)...

Willy...glad the cut went well... ;D...

[willy]

Thanks, first time I ever pulled a big motor and installed one on a big boat, little trikier than doing my 9.9's on my aluminum boats, you need six hands, I only got four :D

[reelapeelin]

So when's splash-down?... 8)...

[willy]

Starting up motor today, going to play with a live well set up also. I have the in floor round one but it was never set up or used , no pumps just a hole with a cover. Hopefully kicker bracket will be here today or tommorow and got to put that puppy in. Looking at next week probably, monday or tuesday.Then I got to learn how to use this Lowrance 3500C and chip. With the new GPS and new lights on board looking to do some night fishing this summer for the first time out of the Highlands. ;) Its nice at night there you have the New York City skyline and Verrazano bridge and a ton of other bridges and lights all around, only time I like the city

[Bygracealone]

Hey Franco and Willy,

Likewise, if you guys ever need somewhere to stop in between NJ and FL, mi casa es su casa.

Steve

[willy]

Thanks brother, but I'm here until the retirement from the PD Florida bound bus trip. It's Franco's turn to run north, he'll need it in a couple of months after he sweats away a few pounds. ;D

[reelapeelin]

A few pounds??...Easy St have Pubah lookin' like Buddah? ;D ;D ;D...

[Franco]

THANKS FOR THE OFFER OZ, AND YEAH I NEED TO SWEAT OFF A FEW - WAITIN' FOR WILLY SO WE CAN DO IT WITH 12 OZ CURLS!!!

THANKS STEVE FOR THE OFFER ALSO

[reelapeelin]

Yeah, Brudda...no 1st hand knowledge, buit I HEAR ::) THOSE 12 oz curls will really knock the pounds OFF!! :) ;D :) :D ;D :D ;D...

Holler if ya need to...love to see ya!!...

[Blue_Runner]

Hey Willy, I got a Johnson 9.9 kicker. It came with the boat. Anyway, I had only used it once on the lake to motor up some skinny water to this restaurant and it did good.

This past weekend I went to the coast and used the heck out of it! I trolled flounder up little narrow creeks. At times I'd see 1.0 ft deep on the finder :o But not to worry! Trolled into the wind and current and was able to steer with the big motor no problem. Target speed was 1.8mph and was attained ;D

I opened her up to see what she'd do for the V-21 and surprisingly I got over 7mph out of it! I'm real happy with it! And, it runs like a sewing machine to be a 1975 model. I told my dad to guess what year and he said early 90's, if that tells you what condition she's in 8)

What length foot you got on that Zuki 9.9? Just my .02, but I think you will need the 20" if not already. A short shaft will likely come out of the water with ya (or get dunked).

If I run both the 9.9 and the 150 at the same time, I should be able to hit close to 50 mph, right ;D :o ???

Just kidding silly!

[Blue_Runner]

Oh and did I mention good on gas? Its amazing how little fuel those motors use. I'm still perplexed. I ran it for probably 5 hours and couldn't tell that any fuel was missing from the original 4 gallons I put in!

[Skools Out]

Hey it's a Ghost oh it's just BR forgot he was around ;D

[Blue_Runner]

:P :P :P

You know you missed me sweetie ;) Now pucker up :-*

[Skools Out]

;D ;D ;D ;D

[76GMC1500]

I use a 4.5" grinder or cold chisels for my non-ferrous cutting needs.