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Old 10-11-2014, 05:24 PM   #1
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How To: Perfect Straight Cuts of Alclad on the Tablesaw

You thought I was nuts and cut it with a table saw didn't you? You could probably do it safely, but I didn't want to risk it.

I needed to patch the old hole where my original furnace used to be. I got a 2x4 piece from vintage trailer supply, lined it up with my table saw fence, then clamped it to the table. The real sweet part of this deal is the shear cutter. Got it at Lowes, and it has a tooth that hangs down. You ride that tooth in the miter slot, so you measure to the edge of the miter slot, and then guide that tooth along the edge. I tried a few pieces oversize until I got the hang of it. Some of the issues were when I didn't clamp well enough and the tool would pull it away from the fence. Other than that, it was great. Perfect reduction to the size I needed. I could even trim it. There was one edge that had a tiny bump out, and I was able to take shavings this way down to probably 1/64".
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Old 10-11-2014, 05:52 PM   #2
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Nice work.
those shears working pretty good for you?
i bought a new set at harbor freight and it sure does not want to cut the aluminum.. i might consider buying the one from lows though.
I been cutting all my aluminum with an air nibbler and then utilize my bench sander to even out the cut...
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Old 10-11-2014, 05:57 PM   #3
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I just put an aluminum blade in the table saw and go at it…
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Old 10-11-2014, 06:03 PM   #4
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I just put an aluminum blade in the table saw and go at itů
Yup. I was surprised at how well it works, even with thicker sheet.

Freud blades rock.
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Old 10-11-2014, 06:06 PM   #5
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I cut aluminum with a circular or table saw routinely. I use a good quality carbide blade. The trick is to turn the blade around and run it backwards for buttery smooth cuts.

Cutting Aluminum Sheet Straight and Long - Airstream Forums
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Old 10-11-2014, 06:22 PM   #6
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Thanks folks for the tips when cutting aluminum sheeting. I have an electric shearing tool that cuts the material okay, but I didn't figure out a good way to make a guide. The table saw slot is an excellent idea. I didn't realize there was a special aluminum cutting blade for a table saw. And good idea with the carbide blade running backwards.

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Old 10-11-2014, 06:45 PM   #7
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Thanks guys. This worked for me, but I was wondering how it would cut on the actual saw.
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Old 10-11-2014, 07:19 PM   #8
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Nice work.
those shears working pretty good for you?
i bought a new set at harbor freight and it sure does not want to cut ...
Spray some WD40 on the blades and down the cut line, it will cut like butter.
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Old 10-12-2014, 03:29 AM   #9
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Thanks guys. This worked for me, but I was wondering how it would cut on the actual saw.
Just like anything would cut on a table saw... They make non ferrous blades for table saws specifically for this application. A trick however is to put a piece of 1/4 plywood down first then cut on that. It narrows the kerf of the blade and give a smoother cut.
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Old 10-12-2014, 09:01 PM   #10
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What brand or number should I ask for at Lowe's? I am a machinist, but I am new to sheet metal and don't know how to order the Shear or read up on using one. Thanks.
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Old 10-12-2014, 09:25 PM   #11
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Been cutting aluminum sheet and angle on the table saw for years. You just have to use the correct blade and a zero clearence faceplate.
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Old 09-09-2016, 01:22 PM   #12
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I normally cut sheet metal with a small 3" circular saw used to cut masonry. The blade has a diamond edge but no teeth to speak of.

I believe I will try this to cut the aluminum patches I need. Clamp the piece down on a 3/4" sheet of plywood and use a rail to guide the masonry saw for a straight edge.

I will let yawl know how it turns our or if any have tried it and failed let me know.
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