Cutting Aluminum

willy

willy

God
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
 
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.
 
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
 
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.
 
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.
 
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!!
 
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 ;)
 
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.
 
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.
 
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
 
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
 
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... ;)...
 
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 :)
 
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.
 
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
 
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.
 
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!
 
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