Metal Magic: Cutting and Shaping Angle Aluminum 

you just put a young soul on some game, thank you

I'm watching all these. My retirement project (I'm 60) is to scratch-build an exact copy of a '69 McLaren M8-B (a Can-Am car). I want to recreate the riveted aluminum monocoque exactly. Recently got the last capability I needed - a complete metal-casting setup for uprights (hub carriers). Great thing is that what was cutting-edge in late '60s racing is now achievable in a decent home workshop!

Dang it. It wanted to see the disc fly across the shop!

Thank you. Another good way to mark angle, is to take the centering tool off of the blade of a combination machinist Square and lay it on the piece of angle, then you can mark both sides evenly and at the same time without having to reposition.

Have you done a video on shop equipment found in a well equipped shop?

Rarely have I ever needed to cut an angle that needed the bottom flange formed to a sharp point. I can only see that use for making a miter joint. There is no weight savings. So cutting the end as you described in the second explanation should suffice for 90% of all such ends. (i.e. marking back 1/8" and drawing the line). You might want to mention that you can cut aluminum at the same speed as for wood cutting, but NOT for steel (4130 etc).

Very helpful video. What type of bandsaw blade are you using to cut through the aluminum angle, TPI and if carbide? I have a task ahead of me to trim 1/8" off approximately 3' lengthwise along a 4' long piece of 1-1/8" aluminum angle to create a mid-span taper. Would you just mark your lines and run the nearly 3' of this angle length through your bandsaw? I was considering using a small circular blade saw in order to ensure a straight cut, what would you do? Trying to leave the straightest and burr free edge possible.

Great video Paul. Quick question, hope it’s not a dumb one. I’ve been watching all the riveting videos and now with this one and notice your work bench always has a piece of cardboard coving it and I was just wondering the reason. Thanks for putting these videos together, finding them very helpful and informative.

Hit the junk bin with the cheap angle on the first toss. Nice.

Just two notes. That is a combination square not a carpenters square. If you used the other side, it will give 45* angles 2: if you used a horizontal bandsaw then cutting 45* is easy, as well as cutting square ends. Using that bandsaw eliminates 95% of what you are instructing. You are using the wrong tool and making a lot of measurement problems to deal with it. 3: BUT...Your band saw can be used with a miter gauge and again eliminate the problematic measuring you are doing. Mark the cut point and run the stock through at a 45* angle. Just like you are doing at 8:33 except using that thing you're using at 5:43 That is not a square it is a miter gauge.

You lost me at 3/8th of an inch.....