Scroll saw cutting 3mm aluminium sheet

Yup, with a metal cutting blade. (and in reality, you might even get away with a fine tooth wood blade)

In 1958 I used an Abrafile on 1/8" aluminium.

Yes, but a nibbler (either electric, air, or drill attachment) would be better if you're cutting from an edge or have a large hole to cut so can make a starting hole that's large enough to take the punch. They don't all go to 3mm so check the spec. I've been using a Falcon drill attachment nibbler for years.

Did you get finished by Christmas?

Bill

Ohh. Must imvestigate.

Bill

Thanks John.

Bill

With correct blade and plenty of oil yes. No oil and blade will clog.

Mike

I've found them to be pretty fast, especially when cutting sheet materials *and* you can hold the sheet firmly. eg, You might have to keep moving it around in a vice or brace the work in the vice with wood / metal strips).

I have an Abrafile 'blade' in a big hacksaw frame all the time (I bought a few at the time).

You can still get alternatives and they are quite versatile:

"RS PRO rodsaw blade is made of tungsten carbide welded to a mild steel rod and is 150 mm or 300 mm long to fit standard hacksaw frames. This tungsten carbide coated blade is suitable for sawing profiles in tile, bricks, concrete, glass, carbon fibre and other composites without fraying the material being cut. It is perfect for maintenance and engineering applications."

The only real limitation is that a std hacksaw does have as big a throat as yer average scrollsaw and whilst you might be able to put one in a coping / fretsaw type frame, they might not be stiff enough for some heavier action.

The only thing to watch out for is the soft aluminium metal clogging up the blade. You might have to rub it with a file card from time to time.

Some aluminiums are worse than others. Oil helps but isn't a panacea.

WD40 is a good cutting lubricant for ali.