_Really_ bad advice.
If you're going to do this, only do it because you're making a habit of
it and really need to. In that case buy a new blade, specifically for
soft non-ferrous metals. Looks just like a plywood blade, but the rake
angle is different. If you're using a chop saw this is a good idea. If
you're using a table saw then it's damn near essential for your
survival - wood blade angles on aluminium will "work", but you're just
asking for a kickback.
Aluminium will also fill your machinery with aluminium shavings. These
are nasty scratchy little things that ruin surfaces of planed timber.
If they ever get damp, then they're also tiny black pencils that will
scrawl on the surface of clean timber.
I've seen many references to cutting aluminum on the TS with a carbide
tipped blade. There are also special blades made just for this purpose
if you expect to do it more than occasionally. Personally, I have never
_intentionally_ cut any aluminum on my tablesaw...
For every complicated, difficult problem, there is a simple, easy
solution that does not work.
I did it twice, latest time was a week ago. The threshold on the
pre-hung door I bought overhung by about 1/2" so I needed to trim it.
This is pretty thin stuff (maybe 1/16) but it still made me
uncomfortable. I used a cheapo combination blade (40T) and as others
have said it makes a mess. I did it because it was thin and I needed a
straight cut I couldn't do with the jigsaw.
It doesn't really cut the Al as much as it smashes through it and sends
pieces everywhere. Goggles are a must and you really need to clean up
afterward because one little speck of the shavings could easily ruin
the next thing you are working on.
Not something I would recommend but can be done in a pinch.
BTW, a backwards plywood blade in a circular saw does a great job on
Yep. I've routed it and turned it on a wood lathe, too.
It will tend to gall on your blades if you cut a lot though. If that
happens, you'll likely have to pick bits of aluminum off from the
teeth of your blade.
But to make a simple square, I think I'd avoid the mess. A pretty
good one can be had cheap, and without dulling your tools or getting
aluminum chips all over.
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