Cutting Aluminum

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Peter Daniel said:

Trust me, the tolerance of the cut is not up to the saw, but depends only on the technique used.



I have a great deal of respect and admiration for your metal work. It is some of the best I have seen, but do you really belive this? If the arbor flange goes +/- .003 every half rotation it can only cut that straignt. I think technique AND the tool are what counts. It is not one or the other.
 
Peter Daniel said:


As mentioned previously, never experienced kick back with aluminum.

Some kickbacks with really large MDF panles, but that was expected.

When I do crosscuts, I always use another board that pushes the smaller piece, then it does not make any difference if it's a crosscut or not.


I will back up poobah on this one. I had to fire a guy once who would not stop using the fence as a stop block. I have seen table saw accidents and do all that I can to avoid them. Having said that, if it seems to work for you go for it. Just stay safe😉
 
Good tools definitely help, but are not neccessary. I seldom upgrade to better ones, and if I do, it takes a while to get used to them again.

In difference to some people here, I don't write about what I think, or what I imagine. I write about what I actually do.

So, I just went to measure 4 plates I recently cut for Patek amp. Each one measured between 1,758 and 1,762, so it's actually better than was suggested previously. If I really made the efort, it could be +/- 0.001" And I did them on a trusted, old Ryobe.
 

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Peter, we know what you are showing.

But, if you show a picture of you working in your live 200 amp panel at home and state that you do it this way all the time without stating how dangerous it can be will get someone seriously hurt if not killed.

All we are saying is it is an unsafe way of using a tablesaw and shold be stated as such.

Good thread thou, I plan on trying some of this stuff in the future.

Bob
 
Runout of the saw arbor is not the major factor in accuracy of a non-ferrous saw. The blade will "flatten out" from centrifual force unless it has been severly overheated or crashed. Then, in the old world, it would be retensioned. That is, struck with sharp hammer blows to reduce the lateral TIR. Typically ~ 0.004".

The most significant improvement in circular blades is the metalurgy of the backing materials, i.e., the ability to make sheet toolsteel (0.062-.250) in a stress free state. This allows the body to be cut with laser, plasma, or water jet without producing "potato chips".

I typically run mills, lathes, grinders, and most types of saws. The one I am MOST cautious about is the table saw. Not scientific but I have been hit by a kickback. It's just me.

As for gloves, my PET PEEVE... This is a popular theme on the home improvement shows. Gloves are a great way to turn a potential nick into an amputation when operating rotating machinery. Sucked into the tool as it were. It's ridiculously stupid. If you are afraid of getting a cut, go sell lingerie.
 
chipco3434 said:
As for gloves, my PET PEEVE... This is a popular theme on the home improvement shows. Gloves are a great way to turn a potential nick into an amputation when operating rotating machinery. Sucked into the tool as it were. It's ridiculously stupid. If you are afraid of getting a cut, go sell lingerie.

You are 100% correct. Gloves are bad news.

-Ken
 
I once worked in a metal shop where we had a huge accident rate because of gloves snagging in the tablesaws. When the boss under WCB pressure made us remove gloves, there were injuries from mini flying bits of metal being embedded in out hands.

The solution was gloves with the fingers cut off 🙂
 
I'm making one last comment in this thread. First, Peter your work is incredible, no one's going to deny it, my intent was not to try to change how you work, (well, okay maybe slightly) but to make sure everyone realizes just how dangerous your style of cutting is. You seem to know how dangerous it is, and think you have it worked out, that's fine. If you read back through, every person who has talked about the dangerous/stupid methods they use, they all have years of experience to explain why they do it that way and are aware that its not a great way to do things. For the newbie just starting out, and thinks "Hey the really cool guys do it that way, so I'm going to do it too", these guys have years of experience and know and understand their tools!

I have learned some things reading this thread and may look into using some aluminum in my woodworking projects, as it appears its easier to work with than I thought, for that I thank all of the expertise in this thread.

One last thing, on the gloves front, I don't even like to wear my wedding band when I'm using saws! I totally agree that cuts and what not are all part of working with wood (or metal in this case) and some basic precautions are a must, but some are more dangerous than what they are trying to prevent. Safety glasses don't cause accidents, breathing masks don't cause accidents, but loose clothing, and jewelry, and gloves all have.

Work safe everyone!
 
From http://www2.worksafebc.com/Publications/Incidents-AllSectors.asp?ReportID=33779

Injury Type : Lacerations requiring amputation of one finger, partial amputation of another
Core Activity : Wood products manufacture
Location : Northern BC
ID Number : 2006109750043
Date of Incident : 2006-Mar

A worker attempted to adjust the kick-back finger on a table saw while it was running. One of his gloves contacted the running saw blade and his hand was pulled into the saw.



Remember, this is supposed to be a fun and rewarding hobby. Safety First!

-Ken
 
I was in machinists school operating one, in a row of lathes. The next row over I saw a girl getting pulled into the carriage of a spinning lathe. Myself and another guy ran over, stomped on the brake and got our arms around her.

By the time the lathe stopped she had one patch of hair on her head... about a 1 inch circle... everything else was gone, wrapped around lead screw of the lathe

Miracles: her scalp was still there... not a drop of blood; we managed to keep her face out of the lead screw and carriage; she was at school the next day wearing a bonnet doing her work.

Tough lesson, lucky girl, tough girl.

Pony tails are bad news. Yes you have to tie them up... but, you also have to put them inside your shirt and make sure they stay there.
 
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