How to Cut Aluminum with a Mitresaw

In this video I will be showing you how to cut aluminum using a mitre saw. Here I am required to cut some aluminum tubing for a boat dock I making. There are two sizes of tubing, one is 2X2 and the other is 2X3. Both are the same in thickness at 3/16”. #aluminium #metalworking #mitresaw
I can purchase specific cut off discs for an angle grinder however, there is an alternative method that most people may have access to.
For this I am using a miter saw with a wood carbide blade. This has ### teeth. There is also a specific carbide blade for cutting aluminum however, this one will do just fine.
First I'm making the rough measurements using a marker. I can make a thicker line with this, then follow up with a scriber to get an exact measurement.
Once everything is marked out, then I’m ready to cut the piece. I have a hose attachment that goes directly to the vacuum cleaner, this does keep the aluminum chips down substantially. The carbide blade also has some candle wax applied, this may help with some lubrication during the cutting process. Cutting oil can be used. However, there is a higher chance of that spraying everywhere.
Once that piece is in place, use a clamp to hold it down so it doesn’t slide on the saw affecting your accuracy.
As you can see, I’m also wearing a mask and safety glasses. Even with the vacuum cleaner, the aluminum chips do travel quite far so it’s best to be safe.
I cut all the pieces as needed. This method does keep the aluminum fairly cool, there is an extremely accurate cut with minimal burrs. I have even used the saw to cut 1/2" thick aluminum in the past. With thicker aluminum, you will need to take your time. Listen for the motor to ensure it’s not being overworked and only apply light pressure down.
Here is another example using aluminum flat bar for a switch panel, this was about 1/4” thick.
Next is some sample footage cutting that tubing, but instead in real time so you can see how long it takes to cut the tubing. All the rest of the footage was sped up previous to this.
When done, then finish up the file to remove any burrs on the edges.
After that the metal is prepped as needed.
Welcome to my channel, Matt's Metalworking. Please don't forget to hit that LIKE button and SUBSCRIBE for future videos. My name is Matt and I produce metalworking relating videos which can include fabrication, machining, milling, turning, welding, tool tutorials, etc.

[@alangolat2907]

This is exactly what I was looking for. No jerking around about nothing. Grab a wood chop saw slam a carbide blade in it and starting sending aluminum everywhere. 10/10

[@TheShizNat]

Thanks; this was very helpful for someone with no metal experience. 👍

[@MattsMetalworking]

You're welcome, glad I'm able to help!

[@megdahlin1118]

Great video for deck rails! Have never tried cutting aluminum so this helps.

[@littlewingpilot]

Funny you should mention that - that's why I watched this , I'm going to use Railblazer's deck rail posts for a cable rail system.

[@megdahlin1118]

Thank you! I'm about to start installing aluminum deck rails. This video will help.

[@MattsMetalworking]

You're welcome!

[@markfavale8404]

thanks man!

[@Trd2020]

Great video! I wasn’t sure if I can use my baseboard blade for aluminum

[@jusgibs]

Had to confirm my plans before ruining my mitre saw blade. Thanks.

[@alanday5255]

Great video, your voice is like butter and your face amazing.

[@jonathanilagan4239]

i know you mean well but this is a strange comment

[@great0789]

@@jonathanilagan4239
Yes.... I concur. 😂

[@StefanDolapchiev]

Would you please share the saw rpm and rake angle of your disc teeth?

[@ThesaconTita]

Could you do this with a 40 tooth blade with carbide tips? I started seeing sparks flying when I tried cutting.

[@MattsMetalworking]

What are you cutting? Are you sure it's aluminum? Aluminum shouldn't spark.

[@Derpherppington]

I brought a 200$ abrasive saw today just to cut aluminum and instantly return it because it’s a pos. It bend, bind , slow and over heat metal and aluminum, it bind itself on the saw , and best of all its doesn’t cut straight 45 no matter what I try. Metal then it’s too slow and overheat. And it left bunch of birch sizes double the material width on every walls. Hercules from harborfreight. Turns out my old blue ryobi with new wood blade cut aluminum like butter quick and cold except for the shaving flying everywhere

[@RustyCas999]

Use an old, cheap carbide blade. This will ruin a fine woodworking blade.