Any advice on how to cut this stuff?
My little jig saw is too much work. I don't have a torch or a band saw...
Would a sawz-all do the trick?

You might try a blade with fewer teeth in you're jigsaw, it should rip right through it.

Sawzall will work, it is essentially a bigger jig saw, with a longer stroke, more power, and a different frame. Other than that, identical. <img border="0" title="" alt="[Razz]" src="images/icons/tongue.gif" />

An 8-inch metal-cutting wheel in a circular saw would work well, too.

Randii

Thanks for the ideas.

"An 8-inch metal-cutting wheel in a circular saw
would work well, too."
A few comments in rec.craft.metalworking said the circular saw would cut very quickly but they recommended using an oil to prevent melting the aluminum and messing up the saw blade.

This fall we used an 8" metal cutting circular saw blade to cut metal roofing. Be sure you take your wallet with you when you go to buy it, because you won't get it for the loose change in your jeans.

I got a 14" ryobi for $139 at Home Depot

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by randii:
<strong>"An 8-inch metal-cutting wheel in a circular saw would work well, too."</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">That's what I used to cut 1/4" thick 6061 aluminum. Aluminum is softer than steel, so it worked fine. Wasn't too difficult.

<small>[ March 10, 2003, 03:43 AM: Message edited by: Jeff the marmot ]</small>

I've cut 1/4" alum sheet (4 ft cut) with a circular saw w/ a plain old carbide tipped wood blade! I asked one of the metal shop techs at my school and this is what he suggested, i thought he was crazy, but i trusted him. just set up a guide and went slowly with some cutting oil. I know it sounds crazy, but it worked really well. the carbide blade works really well as it chips the aluminum instead of grinding it, a lot less heat, it was slightly warm to the touch by the time I finished the cut. similar to any machining process with alum.--keep the heat down.

Wood blades for SawZalls work well. I've cut some 2" thick 7075 T-6 that way. A little beeswax or WD helps a lot.

i've used standard carbide blades as well on aluminum. nothing to it. just go slow and wear earplugs and eye protection. it can be loud!
i wouldn't go this method frequently.. but for a rare need to cut alum plate or rods or whatever.. its fine.

<small>[ April 26, 2003, 10:14 PM: Message edited by: jasonb_exp ]</small>