How to cut a rectangular hole, smaller than 1", in sheet aluminum?

[GWIZ]

Originally Posted by johnyradio

ok, so stone can run faster because they don't overheat the way metal cutters do? thx for that!

I have not paid attention on how hot a stone gets, stones used in hand grinders just cut with better control at a higher speed than conventional cutters with teeth, the little particles break off the stone and you have a new sharp edge not like a cutter that gets dull.

A stone will over heat the material if you are not careful, aluminum gets soft from heat and will pack into the stone.

A stone for cleaning up or sizing is ok. not good the choice for cutting out a pocket.
There are thin slitting types of stones but I would not allow any student too use them.

hoping for a one-tool solution....

There is but not in your price range.

i'm not sure, here are the suggestions that were made:

"Dremel's plunge router attachment, then make a jig/template of the D-sub cutout, and just trace around the template. A proper router bit should cut through the aluminum like butter."

"for what your doing you cannot beat a dremel tool, there is the depth cutter guide attachment that could easily be adapted to follow a pattern. Id get a die grinder and set it up like a vertical spindle sander"

I was referring about trying to cut a cutout with just a rotary tool held by one hand. attachments with a base will help stabilize the tool and can work with the thinner aluminum but may not with your new material, have to see what you find out.

nope

wow, many many thanks, i really appreciate that!!! i know we'll need to buy something at harbor freight, if not this item something else. Would be great if you could donate that!

I'll try to get a good scan of the fine print on the coupon and post it, the way it reads I assume you can just give them the number over the phone. if not PM your address and I will send it to you.
The 25% coupons have been in the penny saver, magazine's, and some free paper they throw on the sidewalk.
When I did frequent Libraries the coupons were in every type of mechanics magazines, you may want to check them out.

BTW: its only good for one item and not the total purchase.

and a scroll and jig would both be considered reciprocating, right?

Yep.

ok, i have read 2 teeth elsewhere.

Can you have too many teeth?
Won't a lot more teeth just give a cleaner, faster cut?

"too many" Maybe not in your case of thin metal.
In thin material it can be cleaner.

Not really faster.
Too many teeth can require more pressure = more heat.
May break the blade from extra pressure.
Less room for chips too escape, chips will pack-up and stop the blade from cutting so you end up pushing harder without thinking and break the blade.

[Scrapper Greg]

Another idea. How about a mortising attachment for a drill press. If you are cutting .010 to .015 steel, I would think it would go through that without a lot of problem. I would try a 3/8" unit.

[johnyradio]

Originally Posted by Scrapper Greg

Another idea. How about a mortising attachment for a drill press. If you are cutting .010 to .015 steel, I would think it would go through that without a lot of problem. I would try a 3/8" unit.

new info: Selkirk has confirmed the piece is 100% 0.017" aluminum.

[johnyradio]

Getting down to the wire. I want to get some kids building these things before xmas, but not looking good.

(Note, Selkirk confirmed the piece is 100% 0.017" Aluminum sheet


the coping saw failed. I could not really control the thing. It just got stuck. The blade was too coarse (15 or 20 tpi). Where i did get a good stroke, just got rough edges. No way i could get those sharp turns. You can see in the pic the trace of the square hole i'm trying to cut.

Awaiting some fine 360-deg spiral blades in the mail, but not sure they'll fit the Stanley coping saw.
http://durafix.com/blades/copingsaw/
and
http://www.bestwayproductscompany.com/products.html

Also waiting for some Stanley 32 tpi blades designed for this saw.
http://www.ebay.com/itm/111231547834...84.m1439.l2649


If the above blades don't work, then on to sub-$100 power tools. These are they:

http://turtlefeathers.net/text/power...son-guide.html
and
http://www.harborfreight.com/16-inch...saw-93012.html
and
http://www.ixi-devices.com/index.php...aw/flypage.tpl

[cutter]

Johny, have you considered a Dremel Multi Tool?
I don't have any experience cutting thin metal with one but I do have the Harbor Freight version that sometimes comes in handy.
They just vibrate through the material so you need a way to dampen loose objects, i.e., hold it firmly, but it might work.

Here's a .

Website.

[GWIZ]

Originally Posted by GWIZ

I'll try to get a good scan of the fine print on the coupon and post it, the way it reads I assume you can just give them the number over the phone. if not PM your address and I will send it to you.
The 25% coupons have been in the penny saver, magazine's, and some free paper they throw on the sidewalk.
When I did frequent Libraries the coupons were in every type of mechanics magazines, you may want to check them out.

BTW: its only good for one item and not the total purchase.

Here is the scan.

http://www.shopfloortalk.com/forums/...ad.php?t=40541

[johnyradio]

Originally Posted by cutter

Johny, have you considered a Dremel Multi Tool?

Thanks, Curmudg!

Keep in mind, i must cut a 1/3" square. So, most Dremel attachments are too big. I believe the attachments that MIGHT work are:

• Cutting wheels, but would have to be 1/3" (7mm) diameter or less. Smallest i'm seeing are 16mm.
  http://www.ebay.com/itm/5pcs-16mm-Mi...item5d413b2210
• cutting bit with plunger, but we're cutting weird-shaped things, so the plunger might be awkward/in the way.
  http://www.ebay.com/itm/Dremel-High-...item4847782575
• Dremel multi-flex attachment, with spiral coping blades. But the throat depth is too short for our needs.
  http://www.dremel.com/en-us/Accessor...PT_MM721_MM725
  http://www.ebay.com/itm/Dremel-Multi...item2a2b7196eb

Someone who is familiar with Dremel, please link me to other attachments that might work. 1/3" square hole, no burrs, sheet aluminum, 3"+ from the edge...

Cost: The cheapest Dremel brand tool i'm seeing is about $25, so i'm looking at Dremel-compatible tools, starting around $15:
http://www.ebay.com/itm/NEW-80-Piece...item27da046b31

[GWIZ]

You get a cleaner cut with a flat blade nibbler opposed to round blades that cut half moons.
Still advise drilling 4 holes one in each corner.

The penny is a little too soft and cut somewhat gummy.

pix 4) One nibbler I was not able to get the penny under the blade, I assume the one with more space is an older nibbler.
requires a 7/16 hole to get the cutter thru, may be able to remove the spring-loaded hold down clamp and get it in a smaller hole.
As I recall there is some other hand nibblers that do not have the clamp and may allow a smaller thru hole.

[GWIZ]

Adel tool co
chicago, ill
made in the u.s.a.

Thats funny, I typed all capitals and the site changed to lowercase

[GWIZ]

No way i could get those sharp turns.

Thats why it has been suggested to drill a hole in each corner.
The wood chisel idea is a good one after you drill the 4 holes.

Originally Posted by Walker

Drill a hole in each corner then use a sharp chisel(woodworking) and hammer through on a block of wood.