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how to drill / cut / shape objects on an aluminium sheet like this.

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  • how to drill / cut / shape objects on an aluminium sheet like this.

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  • #2
    Is this a question or an answer?
    Um, I guess this is where you put something witty.WITTY

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    • #3
      use a dremel. i've just been cutting and shaping some 0.6mm aluminium using one and some cutting disc, with sanding drums and wet/dry paper
      My install... check it out!

      www.mp3car.com/vbulletin/showthread.php?t=56599

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      • #4
        Oooo, using a dremel it will be hard to get nice straight even lines
        -Jesus- King of Kings Lord of Lords

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        • #5
          Originally posted by antimatter
          Oooo, using a dremel it will be hard to get nice straight even lines
          Having hacked my aluminum Shuttle case, I can attest to this.
          I'd use a jigsaw with a metal-cutting blade.
          Have you looked in the FAQ yet?
          How about the Wiki?



          Under normal circumstances, a signature would go here.

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          • #6
            short of a lazer or water cutter you should cut it well inside the line & then file & grind out to your line..... patience..... aluminum is relatively soft & clogs up most cutting media easily, not to mention tranfering heat so well that by the time you cut half way the whole plate will probably be to hot to handle

            don't try to make a cut to your line... work out to your line slowly for perfect results........
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            • #7
              DO you know anyone with a CNC? or a mill?

              If so i suggest you become real buddy buddy with them
              -Jesus- King of Kings Lord of Lords

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              • #8
                Scroll saw would be good. You can use two hands to control the piece and get pretty straight lines. Some simple filing and sanding to finish it off.

                How thin is the piece of metal? I've seen guys tape really thin sheets down to a piece of 1/4" plywood to help keep it from vibrating/bending.

                I'd offer to do it for you, but I don't have a scroll saw right now. Pretty much, you drill a hole ~1/4" feed the special saw blade through and start cutting. 0* turning radius cuts, variable speed, should be pretty smooth.

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                • #9
                  Originally posted by turbocad6
                  don't try to make a cut to your line... work out to your line slowly for perfect results........
                  I concur. This always works for me.
                  Old Systems retired due to new car
                  New system at design/prototype stage on BeagleBoard.

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                  • #10
                    Originally posted by antimatter
                    DO you know anyone with a CNC? or a mill?

                    If so i suggest you become real buddy buddy with them
                    A standard CNC machine can not cut all of that out. It is not possible for a round bit to cut a right angle. Most lasers will not do it either since it needs to be very powerfull. Water jet, powerful laser, or a wire ECM machine would be the way to go if you want it perfect. Again that is if you are looking for perfection and you did not list the material thickness.

                    As mentioned above if you plan to cut it yourself it is best to use some kind of saw. Using a stone wheel on aluminum is a big no no. The wheel will clog with aluminum and can explode. Cut close to the line and file to the line....just like turbocad said. You could also make a jig and cut it with a router table if you have one and then file in the right angles.

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                    • #11
                      i cut mine out with a dremel and sanded back. its not absolutely perfect but its not a bad job either
                      My install... check it out!

                      www.mp3car.com/vbulletin/showthread.php?t=56599

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                      • #12
                        Dremel and then sand it with a "metal sander".
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                        • #13
                          my 2 cent here..

                          I bought and cut something similar about 6 months ago and i needed a flush rectangle. so i bought a nibbler from radio shack - you slide the aluminum into the tooth and sqeeze the handle and it nibbles off a small piece. i use a jig saw to cut close to the line, clamp a straight piece of wood as a guide, nibbled my way down and sanded. it was pretty damn close to perfection. but time consuming. but it didnt required to much sanding. basically what the guys above said.
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                          • #14
                            Air powered nibbler, or even drill powered. cant do 90deg turns bust come at the corners from 2 angles IYSWIM
                            Lez, more widely known as flez1966

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                            • #15
                              Originally posted by lez
                              Air powered nibbler, or even drill powered. cant do 90deg turns bust come at the corners from 2 angles IYSWIM
                              Im not sure if you talking to me or not, but it was a hand tool with a sqaure head.

                              http://www.radioshack.com/product/in...58&tab=summary
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