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Best Way to Cut Aluminum Angles

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  • Best Way to Cut Aluminum Angles

    I wonder what’s the best way to cut 1/8” thick aluminum angle of various sizes with a 10” miter saw.

    Have the angle with one side against the fence and the corner pointing up? (like an inverted V)

    Have the angle lay flat and one side against the fence?

    Have the angle lay flat and one side facing the blade?

  • #2
    Inverted Vee (constant cut force), but that is harder to clamp. Typically L against the fence (clamped) but take it easy going though the flat portion.


    If you are going to cut a lot, foot operated air cylinder (as a clamp) makes clamping a non event,
    Last edited by lakeside53; 12-01-2016, 11:48 PM.

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    • #3
      In an inverted V position, 1/8" angle will be distorted (squeezed to less than 90 degrees) if you clamp it tightly enough to keep it from flipping when you start the cut unless you're VERY gentle. You can be more aggressive once you're about one third through. A freshly sharpened blade works much better.
      Any products mentioned in my posts have been endorsed by their manufacturer.

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      • #4
        A 45 of wood under angles can work well when clamping.

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        • #5
          At one point I had a lot of 1/16 thick angle to cut. I made a temporary wooden fence to back it up and used another piece of wood to nest into the angle and basically pinch it into immobility. Works well.
          I seldom do anything within the scope of logical reason and calculated cost/benefit, etc- I'm following my passion-

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          • #6
            I made a heck of a mess on my prized Bosch 12" miter saw cutting 1/8" angle. I had it in "tent" orientation, and moved too quickly on the initial cut. It snagged and destroyed the blade and damaged the saw. I blogged the whole saga back to sawing health at http://emz3cp.blogspot.com/2015/12/a...ve-lesson.html

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            • #7
              I will choose L against the fence which is also easier to clamp

              Thanks

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              • #8
                What blade do you reccomend? I have a 12" DeWalt. I have never cut aluminum on the miter saw.

                Sent from my SM-G900V using Tapatalk

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                • #9
                  Tent orientation will take the leg at the back into severely positive rake, it try's to pick the Ali up, I found out the hard way too btw so don't beat yourself up, you want one leg flare and one vertical against the backstop, and restrained from lifting with somthing more substantial than fingers!
                  Stick a block on top in the gullet of the angle and clamp down, cut the block as well if you like.
                  Mark

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                  • #10
                    I use standard blades to cut the stuff but the aluminum specific blades work much better.

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                    • #11
                      Originally posted by 6PTsocket View Post
                      What blade do you reccomend? I have a 12" DeWalt. I have never cut aluminum on the miter saw.

                      Sent from my SM-G900V using Tapatalk
                      You must use carbide tip blade

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                      • #12
                        Originally posted by boslab View Post
                        Tent orientation will take the leg at the back into severely positive rake, it try's to pick the Ali up, I found out the hard way too btw so don't beat yourself up, you want one leg flare and one vertical against the backstop, and restrained from lifting with somthing more substantial than fingers!
                        Stick a block on top in the gullet of the angle and clamp down, cut the block as well if you like.
                        Mark
                        Can you please expalin the orientation you recommend? I dont quite understand

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                        • #13
                          Sorry, my spell thingy is suffering from demonic possession, I put the angle into the table to backstop so one leg is flat and the other vertical, I tried tent and fingers and swiftly found out what a 1500 watt mousetrap feels like on your fingertips, ouch F,,,,,Ffff, arse, etc, etc, etc, hence the block of wood and clamp approach, when I worked at an Ali works (the Mrs was a saw operator) they nested them vee towards the operator, apex towards the operator but they were cutting 30 at a time of inch by inch on a pendulum saw with air clamps in 2 planes, she showed me (yes I know) how to cut them idividually, so that's how I do it, I've watched videos of tent cutting but the painful memory of it biting the angle and lifting it makes me cringe.
                          Wax on the blade, or tallow as we used in the Ali works helps a lot.
                          Both me and the Mrs were a bit deaf when we left the place, ear muffs help.
                          Mark

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                          • #14
                            Originally posted by oskar270 View Post
                            You must use carbide tip blade
                            High Speed steel bladed work fine too.

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                            • #15
                              I don’t think fingers can hold any aluminum for cutting, that’s if you value your fingers!

                              I always use clamps and yes I always use muffs which I didn’t when I was younger.

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