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!