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Old 03-08-2015, 08:49 AM   #15
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wow tons of good advice thanks dont have any of those fancy tools
so will try the jig saw and cut from the back using blue tape and oil
thanks again you guys are great

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Old 03-08-2015, 09:07 AM   #16
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I used a metal cutting blade, bought at Home Depot, in a circular saw set for a shallow cut. Avanti 7 in. x 128-Tooth Ferrous Metal Cutting Saw Blade-A07128R - The Home Depot
Even though the blade is for Ferrous material it cuts thin Aluminum just fine.

A saw guide for the straight cuts. Go slow and oil wasn't needed. My plate was thin .040 which helped as well.
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Old 03-08-2015, 10:03 AM   #17
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How much do you need to do?

If more than just a few short cuts then a trip to Harbor freight...

Get a circular saw and a carbide tooth blade with as many teeth as you can get.

Since diamond plate look for larger teeth so longer tooth over more teeth if they are different.

Hearing protection is good too.

Set depth of cut to "just through" where it only is about 1/64 inch more than the material thickness.

This insures the tooth never leaves the material and the amount of bite is very much controlled.

Get a couple c clamps to clamp a straight edge or wood scrap as saw guide for straight cuts.

Get a collection of scrap 2x4 and scatter these on the ground or bench then place material on them.

They space material above surface so no cutting surface.

Push gently and firmly against guide with blade not touching then start saw and then go slow into the cut.
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Old 03-08-2015, 12:04 PM   #18
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I tried numerous things. the only thing that worked was a circular saw with a metal cutting blade. When I made the winter front for my pickup I ended up taking to to a welding shop. They used a nipper on their shear.
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Old 03-08-2015, 01:42 PM   #19
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Consider making a sandwich with luan board or similar with the aluminum in the middle and clamp it all together., You can draw your pattern draw on the wood and make a few test cuts if possible to see which side the ruff edge is left on.

Remember it's really easy to trim the aluminum edges once it's cut using a file or wire wheel.
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Old 03-08-2015, 01:45 PM   #20
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If using a file draw file it...hold file across the material and pull it sideways.

If you have some chalk rub it into the file to prevent clogging.
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Old 03-08-2015, 01:52 PM   #21
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For strait cuts I use my table saw with 60 tooth carbide blade. Forth or fifth for the jigsaw for curved cuts. Just apply masking tape to diamond plate to help stop scratches. Use a file to clean up cuts.
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Old 03-08-2015, 06:22 PM   #22
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Don't forget the wax!
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Old 03-09-2015, 09:59 AM   #23
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Jigsaw works the best. Anything else creates too much heat for aluminum.

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Old 03-09-2015, 03:20 PM   #24
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Being an aircraft sheet metal mechanic for almost 40 years now, I can't believe some of the answers. Sorry fellas, but being a professional sheet metal person, I have to chuckle a bit. No offense intended, so don't get butt hurt, it's not my intention.

The absolute best way to cut that diamond plate is a shear that is rated for the thickness that you're cutting. A jig saw with the right blade would work, along with a skil saw with the right blade. If you have a porous cutting wheel in a high speed cutter, it could become clogged and explode, not highly possible, but possible. If at all possible, find someone or place that has a shear, and have them cut it as close as they can for what you need. Flap wheels (that I get from Ace) seem to work better than regular sanding discs, and a lot better than a sander.

You want to do the work that is needed as fast as you can, otherwise you temper the metal, and it can turn out to be harder to do than when you started. That all depends on what composition that you start with.
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Old 03-09-2015, 05:43 PM   #25
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thanks again will post pics and more imfo as i do this
thank you john
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Old 03-09-2015, 05:51 PM   #26
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Originally Posted by Crippsfl View Post
Cut off wheel is not the best choice. With aluminum the wheel will load up and become useless. Short of the plasma cutter, the fine blade Skill saw is the best choice - unless you have band saw with a fine metal cutting blade.
depending on thickness skill saw for all the straight cuts, jig saw with good wood blade if the alum is not to thick. Done it hundreds of times, eye and hand protection is a must, alum will fly everywhere

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Old 03-13-2015, 01:39 PM   #27
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pop- sicle scores 100 with his blade recommendation. A fine blade will only fill and not cut.
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Old 03-15-2015, 06:34 AM   #28
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Don't ignore the suggestions for ear protection!

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