How to Cut Aluminum Stock

Cutting aluminum stock requires no special equipment to complete and uses the same table saw you use for woodworking projects. What it does require is the use of carbide-tipped blades with plenty of lubrication and a slower cutting speed to deal with overheating issues. Once you've made the necessary modifications, cutting aluminum stock should prove no more difficult than cutting wood with your table saw.

• 1

  Change and reduce the size of the blade used for cutting. Change your table saw blade, mounting a carbide blade with a smaller diameter that those used with the same sized wood stock to slow down the cutting rate. Use lower speed settings on variable speed saws.

• 2

  Lubricate the blade using an old paraffin candle to help cool the aluminum with melting wax during cutting. Place the candle onto the saw table and then feed the candle into the side of the blade while running the blade. The blade will heat the wax, melting it onto the blade. Stop the blade and allow the wax to harden from cooling.

• 3

  Turn on the table saw and feed the aluminum stock into the blade as you would a piece of wood. Use a slow rate of feed when pushing the stock into the blade, allowing the blade to cut through the aluminum slowly but consistently.

• 4

  Cut thin sheets of aluminum by gluing the aluminum to a sheet of plywood using adhesive. Cut the aluminum backed with the board using the saw and then remove the wood backing. Remove adhesive traces with cloth dipped in acetone.