How To Cut Aluminum By Hand | by Tiger Carpenter

I demonstrate how to cut the aluminum sheet into small pieces, in order to create custom jigs or some useful parts / components.
After the cut, some filing or sanding is a good idea, to give the piece of material smooth edges and finish.

[@Seneslau07]

Will I be able to cut lightening shapes, drill holes in a 6mm thick 7075 aluminum allow with different hand saw? I never worked with this allow at this thickness.

[@TigerCarpenter]

Aluminium can be cut, drilled, and routed. It is also relatively easy to process aluminum using hand tools. Just be careful when you cut aluminum with power tools, because you don't want metal projectiles flying near your face

[@Seneslau07]

@@TigerCarpenter Thank you! I know 7075 is high grade and hard that's why I asked.

[@TigerCarpenter]

@@Seneslau07 I'm not familiar with the symbols used for the aluminum. I often melt in a forge and then do some stuff on the lathe or milling machine, and most of the aluminum alloys can be processed without sweat

[@Seneslau07]

@@TigerCarpenter Thanks. I see you're familiar with aluminum, please give in an ideea how could I bend at 90* 1,5mm aluminum sheet to make a box? I might have to find some machine that does that..

[@TigerCarpenter]

@@Seneslau07 depending on your creativity you can make bending device using steel profiles and weld them or bolt them together. I used the door once to bend metal sheets

[@ohnobo14]

Well I’m not buying a miter saw so lets hope I can hand saw some linear rails

[@TigerCarpenter]

hack saw cutting will do. whenever you saw, don't look at the point where the saw is contacting the cut piece. look at the long end of the saw blade, and keep them aligned to the cut line. just like when you ride a bicycle, don't look directly at the front of the front tyre, just look far ahead in front, and control the sides of the road with the corners of your eyes, then you will ride straight. if you look just in front of the bike tyre, you will ride like Slalom Giant.

[@ohnobo14]

@@TigerCarpenter thank you! I have two 4x4 linear motion rails for a 3d printer that I have to cut in half with almost no tools to do so! :)

[@TigerCarpenter]

@@ohnobo14 hacksaw and file to perfection That's the way to go!