Author Topic: Cut 1" thick Aluminum with track saw?  (Read 519 times)

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Offline Cosmos275

  • Posts: 15
Cut 1" thick Aluminum with track saw?
« on: July 29, 2019, 06:44 PM »
Hi all.  I'm looking at using a Festool saw to cut up 1" thick Aluminum plate.  I have done this with my DeWalt curcular saw (7 1/4" blade).  It works alright.  Chips getting everywhere and cutting straight are the main issues.  I'd like to use a track saw because it has a track and also it looks like chips might be collected with a vacuum better than my current setup.  Should I use a plunge cut model or not?  The plunge cut model looks to be better sealed up for chips.  Is 1" thick crazy or no problem?  I don't want to buy a fancy saw just to trash it, but maybe it can handle it.

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Offline xedos

  • Posts: 108
Re: Cut 1" thick Aluminum with track saw?
« Reply #1 on: July 29, 2019, 07:42 PM »
Should cut it, but it’s a bit under powered for 1” in one pass in my opinion.

Be sure to get the proper blade too.  I believe Amana still makes one for aluminum at 160mmx 20mm bore.

Online Cheese

  • Posts: 6532
Re: Cut 1" thick Aluminum with track saw?
« Reply #2 on: July 29, 2019, 07:53 PM »
I've cut 3/8" aluminum plate in a single pass using the TS 55 on a rail...it gives a nice straight cut. Take your time and cut it in 3-4 passes. That should work fine if you use it on a rail. I'd also clamp the rail on both ends because you're cutting in multiple passes and don't want the rail to move. A light spray of WD40 will also help.

The 55 will growl a lot as it's cutting so just take it easy. An aluminum blade is a must, I have a Festool blade but an Amana will work also. I put a dust bag on the 55 and that took care of most of the chips...it fills up fast though. I also turned down the saw speed to either 3 or 4.   
« Last Edit: July 29, 2019, 07:57 PM by Cheese »

Offline Michael Kellough

  • Posts: 4268
Re: Cut 1" thick Aluminum with track saw?
« Reply #3 on: July 29, 2019, 08:58 PM »
I’ve crosscut 1-1/2 x 3 inch aluminum with TS 75.

I used the Walter wax/lube stick for aluminum (on the blade) that Hans recommended a couple years ago. Even though it was only 3” across I felt the beneficial effect of the lube was running out before finishing the cut. It still cut well enough but the visual quality diminished as the lube ran out. With enough lube the cut will shine. Gets dull and cloudy without.

I’ve cut much bigger stock on the table saw. When by myself I sprayed WD40 on the stock along the path of the blade (before making the cut) but it’s better to have someone spray the blade as the cut progresses.

Aluminum shards are heavy (same specific gravity as granite) and they will go far and wide even with a track saw, but not as bad as an ordinary saw.