I'll give that a try with rough cuts done with plasma (as the sheets are 4' x 4') and finish with a table saw. -Am not really fond of using the surface grinder for this purpose as, it's a 1940's Brown & Sharpe #2 that's been completely rebuilt. It holds ten thou across the entire table and want to keep it that way.

Over the years, I've found WD-40 to be suitable for most purposes and usually buy it by the gallon (Much Cheaper that way). In my area there's a discount store called "Ollies" that sells something called PRO-10 -basically identical to WD-40 and cost a $1.50 for 16oz aerosol cans. For milling aluminum, WD works fine for me. I rarely use coolant on the lathe or mill because my production is so low and, since all my work is one-off stuff, I need to see the piece which you cant really do with coolant running.

BTW: I once saw a chemical analysis of WD-40 published by a trade magazine that sent it to a lab... LOL, it's rougly (from memory) 40% kerosene, 40% light mineral oil and 20% surficants and silicone.

Quote Originally Posted by Rambozo View Post
Virtually any woodworking tools can be employed on aluminum. A table saw is great for slicing up sheets, and even a Skillsaw does fine. A miter saw can cut small stock to length. As with wood, carbide blades will have a longer life. A coolant/lubricant will also help. WD-40 or ATF work well. The old timers love kerosene mixed with lard oil for aluminum. I've found nothing better than Tap Magic for aluminum.