What to use to cut Diamond Plate sheets?

[dyethor]

Use a blade made for aluminum and go slow. Or you could try a pneumatic shear. If you live near a fab or welding shop you could see if they are willing to do it cheap. If you brought it to my shop I would do it for a beer.

[Buggy Chief]

Use a blade made for aluminum and go slow. Or you could try a pneumatic shear. If you live near a fab or welding shop you could see if they are willing to do it cheap. If you brought it to my shop I would do it for a beer.

Thanks. I have used a skill saw with a non ferrous blade and it does ok with a straight edge. Just looking for a more precise cut. Thanks for all of the feedback. How do the pneumatic shears work?

[bobwills]

Hmm it just seems it would be a kinda handy way to cut stuff here and there. I wouldnt use it on my good saw though. What about putting a metal blade on a wood band saw. Would that be any good to use or does the wood bandsaws not have a big enough motor on them.

[dyethor]

I have a band saw that uses a little 110v motor with a metal blade. If you don't rush it it cuts sheet metal just fine. Ive cut aluminum, steel, stainless, and copper all with no problem.

[jakeru]

I can tell you that wood bandsaws run at much higher speeds (talking about feet per minute of the moving blade) than metal cutting bandsaws. It might work OK on aluminum though. I hear that generally speaking, a setup that is good for cutting hardwood, works well for aluminum too.

I've seen skillsaws used very effectively for cutting aluminum sheet in the 1/16-1/8" thick range. Clamp a straight piece of wood to the sheet to use as a guide if possible, and use a blade with carbide teeth. Might need to wear hearing protection.

I remember seeing this baby sized skillsaw (circular saw) that worked great on aluminum and was nice and compact too. Its blade was smaller diameter than most and I remember the blade being more lined up with the handle than the average one so it seemed like it wouldn't torque on your wrist and seemed a little safer to me. I wish I had that one.

[edit]
Oh, I almost forgot to add.... I know they make cutoff wheels for aluminum too. I've been meaning to pick one up to try for my 4.5" angle grinder. I have a 4.5" grinding wheel for aluminum and find it's a *really* useful tool. Normal cutoff wheels and grinding wheels are no good for aluminum though, because they load up. The kind made for aluminum seem to shed their abrasive grains more aggressively than standard grinding wheels, and at least for that reason, don't get as loaded up (and actually work.)

[jp2code]

I don't think this is what you are interested in, but adding this for completeness.

No one has mentioned the basic electric jig saw. A jig saw would probably cut through that aluminum as fast and as straight as a Plasma cutter.

[bobwills]

Has anyone cut steel with a circular saw?

[Paul Moir]

Wood working bandsaws work great despite the high SFPM but leave a rough finish. The only real issue is that they can clog up, especially with gummy aluminium. Hosing 'er down with WD-40 helps a lot. You'll know when it happens as the blade stops cutting well and your aluminum gets really hot. Stop and you'll find the gullets have aluminum smeared in them.