Can you cut 6061 aluminum with a circular saw?

31 Oct.,2023

 

Yup, I regularly cut 6061 4 foot by 8 foot sheets down into smaller sections for custom building stuff and to not pay for larger sheets to be cut down by my metal suppliers.

Just make sure you have the proper saw blade (very fine - can't recall exactly what blade I use, but it's lasted years as aluminum is soft) and set a a low depth. Saw itself is my cheapo regular wood cutting circular saw I just swap blades back and forth for wood or metal. Nothing special in the saw category...

Also I lubricate the blade with a paste wax - that comes in a standard caulk gun sized tube........Castrol product but can't for the life of me remember what it's called, but I bought it likely 15 years ago and have never had to even use 1/10th of the tube ever.

I lay down long aluminum level/rulers with soft clamps, and this gives me the ability to cut very long sheets quite well. The tall sides of these long levels also make for foolproof tracking of the saw. (even though it won't wander like plywood.)

The edge may have to be deburred (long board sander with fine grit paper) but for any kind of fab project the cuts are more than straight enough.

I've also been building downforce splitters for my race cars using Alumalite 10mm signboard material, and the circular saw works best as it's fast and does not crush the corrugated material.

Just make sure you degrease/clean the sheets if you are going to weld.

And of course make sure you have a very clean and large workspace to work from for safety reasons......

Oh...and use eye protection and earprotection. It's loud and messy !!


don

 

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