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Cutting aluminum cleanly with basic tools

ROKRIG

425KRAWLERZ
Joined
Apr 3, 2009
Messages
880
So... in the effort to get my hydro reservoir high enough to properly gravity feed my steering pump, it sticks up higher than the hood profile. The hood is made of 6061 aluminum and I need to make a fairly large hole to accomodate the reservoir

What specific tool do you recommend to make the cleanest, most accurate cut. I can buy it from the hardware store if I don't have it already. Keep in mind that the front and side edges of the hood are turned down about 35 degrees to sit on the brackets with the dzus fasteners.

Terry
 
you can also use a plasma but you said basic hand tools so either method mentioned above. be carefull with the saw as mentioned as it will want to grab on an uneven surface but it can be done, use cutting fluid it helps the grabbing a lot.

especially with the grade you have its pretty tough stuff.
 
Thanks guys. After looking at the placement of the reservoir a little more closely last night in comparison to the existing shape of the hood, I won't really need to create a hole but merely enlarge the existing opening.
 
Skill saw with a carbide blade will cut aluminum like butter. Strait lines of course. Hole saw between the lines if you want rounded corners.

One of the smaller (4"-6") cordless units would be a little more controllable.


Fine blade saws-all or body saw and take your time if its something with lots of shape.
 

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