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Topic: Best jigsaw blade for cutting aluminum?  (Read 18462 times)

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« on: February 16, 2012, 12:23:20 pm »

I need to do some long cuts on a piece of 6061 alum. and I'll be using a Jigsaw. Seems to be slow going with a normal metal blade. Of course it is 1/4 thick, so that may be normal. I'm just wondering if there is a blade that will cut faster through aluminum? I do not care about cut quality so much, I will be filing and sanding when done.

I have not seen and specific blades at my local HW stores for alum or other soft metal - they just seem to have wood and metal.
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« Reply #1 on: February 16, 2012, 12:31:43 pm »

the metal blade is likely as good as it will get . . . .the secret with aluminum is to go slow, or the metal will heat and get gummy, and clog up the teeth . . . . .

use massive amounts of lubricant (WD-40 will do), and be patient ... . .
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« Reply #2 on: February 16, 2012, 12:36:14 pm »

There are a few aluminum specific blades out there on the market.

Festool makes a few that are good up to 5/8" thick.
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« Reply #3 on: February 16, 2012, 12:44:59 pm »


the metal blade is likely as good as it will get . . . .the secret with aluminum is to go slow, or the metal will heat and get gummy, and clog up the teeth . . . . .

use massive amounts of lubricant (WD-40 will do), and be patient ... . .


Thanks - that was what I was thinking, and I was going slow and using lots of lube  Thumbsup. Was monitoring as I cut to make sure it was still "flaking" off and not turning to liquid  Lol



There are a few aluminum specific blades out there on the market.

Festool makes a few that are good up to 5/8" thick.


And thanks as well - I will see if I can grab one of those  Thumbsup
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« Reply #4 on: February 16, 2012, 01:15:43 pm »




I have a (I think) DeWalt teflon open tooth, wide-kerf blade that rips through aluminum like it's balsa wood. I'll dig it out this evening and take a picture for you. It's the only blade I've ever used that consistently does a good job. It's about 10 years old.



Nice, thanks  Thumbsup

Anything would beat an inch a minute  Lol
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« Reply #5 on: February 16, 2012, 01:33:46 pm »




I have a (I think) DeWalt teflon open tooth, wide-kerf blade that rips through aluminum like it's balsa wood. I'll dig it out this evening and take a picture for you. It's the only blade I've ever used that consistently does a good job. It's about 10 years old.



I have a similar blade for my circular saw -- wasn't aware they made em for jigsaws, too . . . . good to know, thanks!
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« Reply #6 on: February 16, 2012, 01:51:45 pm »

  I know this thread is about jigsaws but I've had great results using metal cutting blades
in circular saws, table saws and comp-mitre saws.
Quick and clean. Produces dust instead of chips.
If the cuts are straight maybe you should consider a different saw.
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« Reply #7 on: February 16, 2012, 01:54:02 pm »


  I know this thread is about jigsaws but I've had great results using metal cutting blades
in circular saws, table saws and comp-mitre saws.
Quick and clean. Produces dust instead of chips.
If the cuts are straight maybe you should consider a different saw.


I hear ya - it's not the best tool for the job, but it's the best I have. I am slowly building up my power tool collection, and replacing my 50 year old circular saw is next up on the list. Then after that, I'd really like to get a small table saw (which would be ideal).
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« Reply #8 on: February 16, 2012, 02:06:44 pm »

just a data point -- I've got a little tabletop bandsaw I bought from Sears about 15 years ago -- it's happily been cutting aluminum since then (with the metal cutting blade, natch) . . . . I think it cost 99 cash dollars american at the time . . .
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« Reply #9 on: February 17, 2012, 08:49:08 am »


just a data point -- I've got a little tabletop bandsaw I bought from Sears about 15 years ago -- it's happily been cutting aluminum since then (with the metal cutting blade, natch) . . . . I think it cost 99 cash dollars american at the time . . .


A table-top bandsaw is on my shortlist.   Thumbsup
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« Reply #10 on: February 17, 2012, 11:39:06 am »


use massive amounts of lubricant (WD-40 will do), and be patient ... . .


I got the same advice from this girl I used to date.......    
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« Reply #11 on: February 17, 2012, 12:01:25 pm »




I got the same advice from this girl I used to date.......    


To use wd-40?    Crazy
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« Reply #12 on: February 17, 2012, 12:08:30 pm »

I guess she was trying to get the squeaking to stop.
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« Reply #13 on: February 17, 2012, 05:21:03 pm »


I guess she was trying to get the squeaking to stop.


Didn't realize it was the headboard?
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« Reply #14 on: February 17, 2012, 09:52:58 pm »

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« Reply #15 on: February 17, 2012, 10:57:17 pm »

If by chance you change your mind about the power saw choice.. I have used on several occasions a circular saw with a rough cut tooth count carbide tipped blade on aluminum plate up to one inch thick.  A steady feed rate and ear and eye protection are a must. This method will throw sharp edged hot chips for a considerable distance..  Plunge cutting however tends to be dicey. Embarassment

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« Reply #16 on: February 18, 2012, 07:45:34 am »




Didn't realize it was the headboard?


Didn't say it was.....
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