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09-11-2016, 08:19 PM
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#1
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3 Rivet Member
1962 19' Globetrotter
2001 31' Excella
Join Date: Aug 2002
Posts: 247
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Cutting Aluminum
I'm about to start a repair project and looking for thoughts on the best way to cut aluminum to shape before for a large patch. Thanks!
Sent from my iPad using Airstream Forums
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09-11-2016, 08:24 PM
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#2
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Rivet Master
1971 25' Tradewind
1993 34' Excella
Currently Looking...
Estancia
, New Mexico
Join Date: Feb 2005
Posts: 7,743
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I assume you are talking about aluminum sheet. Electric Shears (nippers) if you are going to be doing a fair amount of cutting. Harbor Freight shears work good.
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Sail on silver girl. Sail on by. Your time has come to shine.
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09-11-2016, 09:36 PM
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#3
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Rivet Master
1999 34' Excella
Currently Looking...
Hillsboro
, Texas
Join Date: Feb 2013
Posts: 6,408
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For large thicker aluminum sheets I have used a tool called a "nibbler". It basically nibbles out uniform notches.. You just carefully guide the tool along a clear line or arc guide and it just does a clean job with minimal edge lift/distortion.. There are hand type and electric. The electric will do an amazing job...less hand effort, but huge cost
Lift
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Peace and Blessings..
Channing
WBCCI# 30676
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09-11-2016, 09:41 PM
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#4
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Rivet Master
1972 31' Sovereign
1975 31' Excella 500
Currently Looking...
Benton
, Arkansas
Join Date: Mar 2013
Posts: 5,868
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Cutting Aluminum
For those with a steady hand a pneumatic cut off wheel is hard to beat.
A band saw with a narrow blade can work very well too.
Gradiens super tenui glacie.
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The fact that I am opinionated does not presuppose that I am wrong......
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09-11-2016, 09:45 PM
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#5
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Rivet Master
1969 25' Tradewind
Shasta Lake
, California
Join Date: Sep 2012
Posts: 1,040
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I used the Harbor freight electric shear on my project they work great.
I also used the hand shear and the hand nibblers for tight areas .
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09-12-2016, 05:48 AM
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#6
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3 Rivet Member
1962 19' Globetrotter
2001 31' Excella
Join Date: Aug 2002
Posts: 247
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Would a jigsaw work?
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09-12-2016, 06:48 AM
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#7
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Rivet Master
1956 22' Flying Cloud
1953 32' Liner
1955 22' Safari
Valley View
, Texas
Join Date: Jan 2006
Posts: 3,971
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be careful
Most of the suggestions you see here will leave you with an edge which won't look good and be difficult to work with to make it look good. Any...ANY....small "wobbles" and cut marks will show. Filing to an "edge" is hard. Just measure it and take it to someone who has a shear. Now, on a small patch you can get away with those other cutting tools.
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"If it can't be reduced, reused, repaired, rebuilt, refurbished, refinished, resold, recycled or composted
then it should be restricted, redesigned or removed from production."
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09-12-2016, 07:25 AM
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#8
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4 Rivet Member
1976 25' Caravanner
Salt Lake City
, Utah
Join Date: Oct 2013
Posts: 398
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Careful use of a bench-mounted belt/disk sander will smooth out the edges very nicely.
Lots of good advice about tools and techniques on these forums. Also many good demonstrations on YouTube.
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09-12-2016, 07:37 AM
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#9
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Rivet Master
1971 25' Tradewind
1993 34' Excella
Currently Looking...
Estancia
, New Mexico
Join Date: Feb 2005
Posts: 7,743
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Quote:
Originally Posted by Craig
Would a jigsaw work?
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Yes, but in my experience hard to cut with a jigsaw without a lot of vibration.
__________________
Sail on silver girl. Sail on by. Your time has come to shine.
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09-12-2016, 08:20 AM
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#10
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4 Rivet Member
1976 25' Caravanner
Salt Lake City
, Utah
Join Date: Oct 2013
Posts: 398
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You can spring-clamp sheet metal (ie., aluminum) onto a piece of plywood. Keeps it from bouncing around as you cut it. Better yet, sandwich it between two pieces of clamped plywood. Variations on this procedure are many.
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09-12-2016, 08:38 AM
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#11
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Rivet Master
2002 30' Classic S/O
Fleming Island
, Florida
Join Date: Nov 2013
Posts: 4,673
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I opened up the ceiling under a light in my Safari with a Harbor Freight pneumatic nibbler. It worked great. It does leave a rough edge, so if the edge is going to show you would have to smooth it with one of the techniques mentioned earlier here. In my case, the light covered it up, so no worries.
Al
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2002 Classic 30 Slideout -S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
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09-12-2016, 09:12 AM
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#12
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Rich and Kat
2017 30' Classic
Alexandria
Alexandria
, Virginia
Join Date: May 2016
Posts: 275
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Hilti and others make circular saw blades for cutting non-Ferrous metal as well as steel. Never used one but they look cool. I will get a blade for my Festool Kapex (chop saw) but haven't needed it yet.
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Rich
2017 Classic 30', ProPride 3P Hitch, 2016 RAM 3500 Laramie Crew Cab 4x4 SRW w/ 6.7L Cummins Turbo Diesel and Retrax Pro MX Tonneau Cover
KB2ZMF Save
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09-12-2016, 09:29 AM
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#13
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4 Rivet Member
Vintage Kin Owner
Superior
, Colorado
Join Date: May 2014
Posts: 442
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I have a red 10" sawblade I got at Home Depot, brand is escaping me, for non-ferrous cutting. In my tablesaw it cuts thick aluminum like buttah. It's astounding. I need to try it on the 0.032 aluminum I have.
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1972 33' Streamline Emperor Crown Imperial
1949 30' Spartan Royal Mansion
2012 Nissan Armada
Most of China
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09-12-2016, 10:18 AM
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#14
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Rivet Master
1971 21' Globetrotter
Currently Looking...
Currently Looking...
Currently Looking...
Arvada
, Colorado
Join Date: May 2006
Posts: 3,530
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I use this
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09-12-2016, 10:29 AM
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#15
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2 Rivet Member
1976 25' Caravanner
Kansas City
, Kansas
Join Date: Nov 2015
Posts: 52
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Quote:
Originally Posted by Aerowood
I use this
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Drool...
Also, for most aluminum sheet thickness that would be used on an Airstream you can score a line with a knife a few times and then it will fracture when you bend it back and forth a bit. You can get a pretty clean edge in most cases but it is really only viable for straight cuts.
Aerowood probably has some additional advice on this topic of scoring aluminum.
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09-12-2016, 10:58 AM
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#16
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Rivet Master
1972 31' Sovereign
1975 31' Excella 500
Currently Looking...
Benton
, Arkansas
Join Date: Mar 2013
Posts: 5,868
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Quote:
Originally Posted by Lumatic
Yes, but in my experience hard to cut with a jigsaw without a lot of vibration.
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Mount the edge you are cutting very close to the edge of a bench to mitigate this.
Gradiens super tenui glacie.
__________________
The fact that I am opinionated does not presuppose that I am wrong......
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09-12-2016, 12:30 PM
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#17
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Rivet Master
1964 26' Overlander
1974 31' Sovereign
Milton
, ON
Join Date: Oct 2002
Posts: 1,224
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Quote:
Originally Posted by ericpeltier
I have a red 10" sawblade I got at Home Depot, brand is escaping me, for non-ferrous cutting. In my tablesaw it cuts thick aluminum like buttah. It's astounding. I need to try it on the 0.032 aluminum I have.
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I have found that a table saw will work well for straight cuts in aluminum sheet. Use a zero clearance throat insert and make sure the aluminum sheet can't slip under the fence. You can either clamp a piece of angle aluminum to the fence and run the aluminum on top of it, or run it through with a piece of scrap plywood underneath the aluminum. I find that it's also helpful to run a piece of wood on top of the aluminum with the blade set below the top surface of the wood. This helps to keep the aluminum from vibrating and reduces the number of aluminum chips being thrown back at you.
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09-12-2016, 01:17 PM
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#18
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Rivet Master
1971 21' Globetrotter
Currently Looking...
Currently Looking...
Currently Looking...
Arvada
, Colorado
Join Date: May 2006
Posts: 3,530
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Quote:
Originally Posted by LifeIsRiveting
Drool...
Also, for most aluminum sheet thickness that would be used on an Airstream you can score a line with a knife a few times and then it will fracture when you bend it back and forth a bit. You can get a pretty clean edge in most cases but it is really only viable for straight cuts.
Aerowood probably has some additional advice on this topic of scoring aluminum.
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Well, as a matter if fact I do, I have always called it a Skin Knife. Its made from a file
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09-12-2016, 01:49 PM
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#19
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2 Rivet Member
1976 25' Caravanner
Kansas City
, Kansas
Join Date: Nov 2015
Posts: 52
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Ah yes, thanks for the trade secret!
That is exactly the image that was burned into my brain. Although I've successfully used the scoring method with various shaped razor blades the skin knife looked much more robust. I remember googling "skin knife" half a year ago and coming up with nothing. It's not often that a google search comes up empty handed, haha.
Any suggestions as to the shape of the modified file?
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09-12-2016, 02:03 PM
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#20
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Rivet Master
1971 25' Tradewind
1993 34' Excella
Currently Looking...
Estancia
, New Mexico
Join Date: Feb 2005
Posts: 7,743
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Quote:
Originally Posted by Aerowood
Well, as a matter if fact I do, I have always called it a Skin Knife. Its made from a file
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I have not heard of a skin knife before and have not used the score method on aluminum. I have used a utility knife on sheet metal and it works.
__________________
Sail on silver girl. Sail on by. Your time has come to shine.
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