Re: Cutting an Al box profile

Hi,

Would like to know the best way (w/accuracy) to cut a standard 4" Al box profile.
Need about 10 pcs. 4"x 4"

Any ideal where I can have this done properly and cleanly ?

Thanks. 🙂

You need a miter saw. If you don't have one, just drop by at any glass & aluminum shop near your area and have them cut for you.

Re: Cutting an Al box profile

Went to 3 of these Al fabricators, and all of them begged off. They can only do straight cuts, no bevels or angle cuts and they said they cannot guarranty a clean cut.

Using a standard 4" box Al profile (4" x 1 5/8") if I'm not mistaken.
The piece i need is a 4 inch square on the bottom side and the top side is 4& 1/2 inches.

They said the best way to cut it is using a simple hack saw, but they will not do it.

So, what to do now ? Any suggestions ?

Does anyone have a 'very flexible' mitre saw that can do bevel cuts ?

Cheers 🙂

Re: Cutting an Al box profile

who is Al anyway... :p
maybe you need to look for Mac to fix your prob... :rolleyes:

Re: Cutting an Al box profile

That is very funny !! 🙂 but this is serious...

"Al" refers to Aluminum as you can see from any Periodic Table.

So, an 'Al box profile' is an Aluminum box profile which is a standard (extruded) Aluminum product that is used to make Eg. door jambs of Aluminum doors and such.

Seeing as those Al fabricators do not seem to want to cut the Al box, then maybe I can do it myself.

Plan A: I know if I use a basic hacksaw, maybe even using a 24 or 32 teeth blade, then i need to make a jig of some sort, one for the straight vertical cut and another for the 'bevel' portion on the other side. The 32 tooth blade is the easiest to use here, anybody have any idea WHO SELLS 32 teeth hacksaw blades ? I haven't found them anywhere in Manila.

Plan B:
I posted this on another thread of 'Flavio' (?) suggesting that a thread on metal-working ought to be started...

If anybody has seen on Discovery Turbo, the show 'American Chopper,' they always use an angle grinder with some sort of a metal cutter or blade that cuts through gauge 16 sheet metal.
Now that is something I might be interested in getting (for myself) so that I can do this project myself.

Anybody knows what I need to buy ? The 4" Angle grinder is easy to get, but what about that blade that cuts through the sheet metal ??

Thanks

Re: Cutting an Al box profile

I am aware that Al is aluminum, but other can easily mistake it for something else, having said that, when I said Mac, I meant Machine shop, now see how confusing some abbreviation can be mistaken for something else.
now clearing the air, you need to cut an aluminum piece to 4"x 4" x from what size?

Using a standard 4" box Al profile (4" x 1 5/8") if I'm not mistaken.
The piece i need is a 4 inch square on the bottom side and the top side is 4& 1/2 inches.
so you are using a standard 4" box Al profile ( what is a standard 4" box Al. profile anyway?) and you want to cut it into? dang, this is so confusing...

Does anyone have a 'very flexible' mitre saw that can do bevel cuts ?
Why would you need a flexible saw? does your box have a wavy side? Miter saws can cut bevels, no need for a flexible one? Never seen or heard one anyway.
Cheers 🙂

and from your initial post which you wrote...

Would like to know the best way (w/accuracy) to cut a standard 4" Al box profile.
Need about 10 pcs. 4"x 4"

where in the world did 4" x 1 5/8" and 4" and 1/2" come from?

do you have a picture of what you want to achieve? from what you wrote, I can't make heads or tails on what you want. I tried to understand it really but I can't. I want to help you maybe someone does too. so unless I or we know what you specifically want to do... the point is mute. if you have a picture, a link, a drawing, a sketchup or anything that we can see, please post it.

don't get mad but we can't help you if we can't understand what you like.

That is very funny !! 🙂 but this is serious...

and yes I am serious too... I think...

Re: Cutting an Al box profile

Thanks Timber, will clarify as best as I can.

The Al box profile is a standard extruded Al product that you see in all Al fabricators &/or anodisers. Swan Alumnium is a company that comes to mind. They used to do all my electronic chassis requirements. They cannot now because they dissolved their Al fabrication dept.

This 4" box profile has rectangular dimensions of Width 4", Height is (correction) 1 & 3/4" and the length is usually 20 feet.

I have to cut this in approx 4" lengths, and if you look at it side view, (looking along the 1&3/4" side) the back cut is a standard straight 90 deg vertical, the front cut is beveled or at a slight diagonal.
[____/ <------ something like that, although there is a line at the top, I just do not know what character to use.

With a manual hack saw & 32 tooth blade, I know I can do it, but I need to make a 'mitre box' of some sort so that my cuts will be straight and true.

The 4" angle grinder can do also, but what do you call the cutting blade for metal ? Problem here is that it will be difficult to handle and cut straight lines.

Anybody know where I can get some 32 tooth hack saw blades ?? 24 teeth would do but the 32 would be easier to cut with.

I can take a picture of the thing I need but I do not know how to upload the jpeg.

Cheers,

Re: Cutting an Al box profile

Im thinking that a miter saw with a 100 or 120 tooth blade could cut that bevel on the aluminum, the only thing is im not sure if the blade will reach all the way through when beveled like that.

Re: Cutting an Al box profile

get a picture of the main material. I agree that a miter saw can handle the work... I have cut aluminum on it as thick as 1/2" without a hitch. I reckon 1 3/4" should not be any different. now should the cut not be smooth, a file or sandpaper should make short work of it.
maybe a picture or a sample is available online that you can post a link...

Re: Cutting an Al box profile

Pls consider also that a 4 inch angle grinder will probably not reach the depth nor width that you want and to keep it perpendicular with. Hand holding it for the accuracy you mention is very doubtful.

A larger cut-off machine with a 10 inch blade may do the trick. The plumbness you need will be consistent.

The blade for your intentions is not a special blade although you should look for a thin cutting blade, because aluminum is a soft metal and your project isn't that thick, most power tool suppliers carry them.

HTH. 🙂

Re: Cutting an Al box profile

thanks JohnJo, Timber,

I agree an angle grinder cannot cut through, but if I cut one side at a time, then it will work, Now as to the accuracy, trueness of cut well that is another story but if I allow an extra margin when I cut, then I can grind away/file away the excess and 'fix it' ... phew, sounds like tedious work, but I have the time, am not in too much of a hurry.

What about making some sort of a mitre box and using a hack saw. I can cut one side at a time but the 32 tooth hacksaw blade.

Wasn't there a local online hardware that came out in one of the threads. Somewhere in EDSA near Channel 7 if I remember correctly. I know they carry that item in stocklist.

What can I put in the search box ??

Thanks 🙂

Re: Cutting an Al box profile

Few days ago, I bought a box (miter box) which has 90 and 45 degrees slot for cross cutting and bevel cut. Miter box is design for back saw which has 11 to 20 teeth per inch. But I'm not sure if that can cut Aluminum. Somebody already has a back saw here, maybe they could help.

Miter box is around 500 pesos in Handyman

Re: Cutting an Al box profile

Hi,
It's been awhile since I posted, I install and fix industrial aluminium machines. What can be used is an appropriately sized miter saw. Its the type of saw blade that you need. For aluminium the best blade is one with a negative rake and with alternating flat and square tip. In its absence any thick carbide tipped saw blade will do. Cut slowly and do make sure you have drip oil on the cut and USE SAFETY GLASSES!!!.

Re: Cutting an Al box profile

Hi,
It's been awhile since I posted, I install and fix industrial aluminium machines. What can be used is an appropriately sized miter saw. Its the type of saw blade that you need. For aluminium the best blade is one with a negative rake and with alternating flat and square tip. In its absence any thick carbide tipped saw blade will do. Cut slowly and do make sure you have drip oil on the cut and USE SAFETY GLASSES!!!.

how thick? what is the usual thickness po ba ng saw blade for aluminum? is the number of tooth also important for aluminum cutting?

Re: Cutting an Al box profile

Hi,
It's been awhile since I posted, I install and fix industrial aluminium machines. What can be used is an appropriately sized miter saw. Its the type of saw blade that you need. For aluminium the best blade is one with a negative rake and with alternating flat and square tip. In its absence any thick carbide tipped saw blade will do. Cut slowly and do make sure you have drip oil on the cut and USE SAFETY GLASSES!!!.

i treat my eyes as the most precious for my occupation but equally important are my ears...miter saws are known to screeeech a lot that may reach more than 100 decibels..more so when cutting aluminum.