how to depth cut composite aluminium panel

**Franz** · 9th June 2013, 09:43 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.

Originally Posted by PhilipA

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

Phillip,

You need a triple chip blade designed for aluminium. I have a 10" saw which runs a standard 30 tooth wood blade - the aluminium cutting blade, by comparison, has 80 teeth. Every second tooth has bevels on it whilst the others have a square tooth.

It is possible to cut aluminium with a regular blade but it's dicey (as you have already found out). Use caution when cutting alu with regular wood blades - it only takes one incident in 100 to do damage.

Cheers,

Franz

**Sitec** · 9th June 2013, 10:35 AM

As said before, router with vee bit or circular saw. If you use a vee bit, a thin line of Sikaflex run up the fold then wiped off once folded works quite well. Remember though that your corner is only as strong as the .8 alli sheet on the outside of the fold. For cutting the stuff we use 125mm thin cutting disks on grinders. Works quite well.

**PhilipA** · 9th June 2013, 10:57 AM

I have bought a second hand Ozito plunge router on ebay , which appears to have a 90degree bit with it, and it has a fence. I know they are probably not all that good but should be OK as long as I can set depth accurately.
Its a big one

Plunge Router Kit 1600W Ozito PRG-632VK Router/cutout tool

So away I go. I should be able to use it to depth cut checkerplate etc also to help fold.
I will probably add it to my list of rarely used tools , but I do tend to use them occasionally.
Regards Philip A

**worane** · 9th June 2013, 03:38 PM

I bought an Ozito small router a few years ago. Whilst I don't use it often it has always worked just as well as my two big routers do.

**rijidij** · 9th June 2013, 09:45 PM

Sounds like you have some Alucabond or similar. The correct way to groove it for bending is with a flat at the bottom of the 'V'

See pic below or the whole spec sheet here........ Alucabond fabrication

Cheers, Murray (27 years as a cabinet maker in a previous life

)

**uninformed** · 14th June 2013, 02:30 PM

or you could have used your circular saw set to 45 degrees, just make two passes, 1 from one direction, the 2nd from the other. The correct depth is to cut everything but the face layer, ie through 1 sheet of alu and all the way through the body (formica) leaving the outer layer in tact for the fold.

**PhilipA** · 14th June 2013, 02:58 PM

I have picked up my router now and it has a 90 degree bit, so it looks like 2 passes 3MM apart.

Typically I bought the second hand one on ebay and ALDI has them for $49 next week. Although mine is 1600W with what looks like 1/2 inch shank and theirs is 1200W with 1/4 shank.
So now I have to measure up everthing, taking into account the rivets and 90 degree aluminium I will have to use on the corners. I thought i would fill the folds with 2 pack epoxy to add strength.

Regards Philip A

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