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.