Cutting aluminum plate on an ROS. Do-able?

I have cut that stuff on a table saw, a mitre saw, and a band saw... but I wouldn't even think of doing that on a radial arm saw.

Doable? Yes. But a tablesaw would be better and safer. You did notice that the plans call for 1/4" Al bars? Your 1/8" will probably flex too much to be really functional. Art

Works well enough--I've done it on occasion. Just take your time and wear good eye protection (goggles that seal to your face and a face shield over them)--you're gonna have fine sharp edged chips flying around and one of them in your eye can ruin the rest of your life.

----------------------------------------- Thought for the day:

Take the tent pole down, Put the flag away, Monkey had a hemorrhage, There will be no performance today.

Throw the existing 1/8 pieces in the scrap bin.

Proceed down to your neighborhood hardware store and buy a 1" x 1/4" x

Return home and cut 7-1/2" long pieces on bandsaw per spec.

(Cut 1/16" proud and clean up cut square with mill bastard file.)

Have a beer and enjoy your accomplishment.

Not picking on you, we've all been there.

Lew

How many jigs are you planning to make? Home Depot carries 1" x 1/4" aluminum stock. Cut it with a hacksaw and hit up the cut ends with a file. Save the plate for when you need plate.

Hey, life just got easier. If I can get this as presized stock at Ace or Home Depot, that takes care of that.

Thanks to all for the wake-up calls.

Don't forget the beer prescription.

Have cut much Al on a RAS with a special non ferrous blade. Just don't do a climbing cut. Of course all the PPE should be used.

I have no qualms in doing so, just be sure the stock is well secured. I was once ripping an aluminum yardstick into narrower pieces and it wound up wrapping itself around the blade ruining a nice, slightly over 1/16" Japanese thin kerf blade.

To each his own.

#1. A ROS is a random orbit sander, not a radial arm saw

#2. I've been a carpenter for over 50 years. I would never use a contraption like that shown to cut a hinge mortise. Consider a router bit with a top bearing. Cut a hinge template that is an accurate fit for the hinge itself. Simple and repeatable. I own the Rockwell set and a Bosch set. I use my simple homemade templates unless I'm cutting 10 or more doors. No re-thinking, matching collets and bits, calculating.

#3. Aluminum cuts just fine on anything that can cut wood. The cuts will NOT be smooth. If you can buy bar stock, do so.

Personally, I just reach for a wood chisel and mallet and do it just like I was shown many years ago.