how to depth cut composite aluminium panel

**PhilipA** · 7th June 2013, 05:51 PM

I have bought several composite offcuts to use as shelves for plastic drawers in my D2. I have made the whole setup with Qube lock and now I thought it would be nice to make a drawer above the fridge in free space.

I would like to fold the composite which is thin painted aluminium both sides with about 3MM of formica type material between. Very light and strong and usually used to make signs..
I guess that I should score the composite with a groove half way through so that I can right angle fold it to make drawer ends and sides and I am wondering the best way to do it at the minimum cost. I have cut the composite to size using a 184MM circular saw with 40 teeth, and it has made a good cut.
After whacking my thumb I found that thin aluminium angle and drop saws with 40 teeth don't mix and I don't want to ruin the composite by plucking off the aluminium.
Has anybody had experience with depth cutting composite so that it can be folded and how to do it? Do I just set the circular saw at a shallow depth or use a router or any other suggestions. Or should I just cut it and use aluminium angle to join sides and bottom.
Regards Philip A

**p38arover** · 7th June 2013, 06:07 PM

Table saw or radial arm saw, perhaps?

Do you know anyone with one or the other? (I have both but I'm too far away.)

**Bradtot** · 7th June 2013, 07:52 PM

You need a V groove bit and a CNC router.
If you were over here I could do it for you as these machines are what I install and fix and we have many clients that do this as their main line of work.
Sorry I cant be of more help

Brad

**PhilipA** · 7th June 2013, 08:48 PM

I might try a sample cut with my hand held circular saw using a fence.
The kerf looks about 2 mm so I might get enough out to bend it 90degrees. Doesn't have to be perfect as it is for me and I can fill gaps with white Sikaflex.LOL
I saw on Utube the good gear to do it but mucho dinero. Nobody seems to do a cheap router! I wonder how a dremel would go with the grout attachment.
Regards Philip A

**p38arover** · 7th June 2013, 09:16 PM

I have a router and a V-bit.... but you are too far away.

**slug_burner** · 7th June 2013, 09:42 PM

Originally Posted by PhilipA

I might try a sample cut with my hand held circular saw using a fence.
The kerf looks about 2 mm so I might get enough out to bend it 90degrees. Doesn't have to be perfect as it is for me and I can fill gaps with white Sikaflex.LOL
I saw on Utube the good gear to do it but mucho dinero. Nobody seems to do a cheap router! I wonder how a dremel would go with the grout attachment.
Regards Philip A

Don't know what a grout attachment is but the dremel is just a rotating tool, the appropriate cutting bit should do it, just have to keep the feed rate low due to the low torque on the dremel.

You can use your circular saw and a fence. If you are concerned with pulling the aluminium veneer off then run the saw back over the material instead of having the teeth pull the veneer up the back of the saw will push it into the material. That is the recommended way of cutting laminex to avoid chipping the the coloured surface.

**p38arover** · 7th June 2013, 09:45 PM

Originally Posted by slug_burner

run the saw back over the material instead of having the teeth pull the veneer up the back of the saw will push it into the material. That is the recommended way of cutting laminex to avoid chipping the the coloured surface.

Thanks for that tip.

**Hoges** · 8th June 2013, 06:22 AM

Depending on the diameter of your saw blade ...if it's a biggie you could buy a cheap(ish) 80 tooth blade for aluminium... and run it backwards as suggested previously. Btw ... how did you cut the Qube lock? Circular saw?
Looking frwrd to seeing "illustrations"!!
Cheers

**PhilipA** · 8th June 2013, 08:03 AM

how did you cut the Qube lock? Circular saw

I cut it with a Ryobi drop ( mitre) saw which I was given when I bought some other Ryobi battery stuff. It has the standard 40 tooth 214MM blade but cut the Qubelok cleanly with no hassles. I thought I would give it a go though the best is to use a 60 tooth blade. I oiled up the cut with WD40.
However when I tried to cut some thin 25MMx 25MM aluminium angle , it lifted and jammed so no go, and I had to use a hack saw.
Regards Philip A

**numpty** · 9th June 2013, 09:35 AM

Originally Posted by PhilipA

I cut it with a Ryobi drop ( mitre) saw which I was given when I bought some other Ryobi battery stuff. It has the standard 40 tooth 214MM blade but cut the Qubelok cleanly with no hassles. I thought I would give it a go though the best is to use a 60 tooth blade. I oiled up the cut with WD40.
However when I tried to cut some thin 25MMx 25MM aluminium angle , it lifted and jammed so no go, and I had to use a hack saw.
Regards Philip A

The reason for that is not enough teeth in contact with the surface while cutting.

2 teeth or more is the go, if I recall. I mostly play with timber these days, but the same applies.

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