Pitts LG

Hey, Jim. I have a variable speed jig saw that, with a new blade (cheaper than a band saw blade) that would work well...

Bob

I would use a dremel tool with a cut-off wheel.

Dick

I am assuming you are better with a jig saw than I am. . . .

Dremel and a cutoff wheel, or two, or three? That's how I cut my music wire.

Morris

You can use my poor mans band saw. An upsidedown jig saw in a vice, and a packet of fine tooth blades.

You can use my poor mans band saw, an upsidedown jig saw in a vice. Pick up a pack of fine tooth blades too.

Jim, Sounds to me like you would be happier with a tank than an airplane. I do fabricate a lot of aluminum parts..take it from experience..6061 will not hurt your bandsaw blade. A little WD40 along the cut line will keep the blade clean. But my concern is that the additional weight of that much aluminum, especially that far below the thrust line, will affect the axial performance in a very negative manner.

Phil AMA609

That very well may be, but I already KNOW that 5/32 aluminum gear on a 14 to

You're right, Six, it won't. I ended up with 3/16" on my 15# Dr.1.

You can cut Al with a metal bandsaw blade, hacksaw, or you can grind it with a Dremel-type cutoff wheel.

I don't think the slight extra weight of the 6061 Al gear will make much difference to the flying characteristics. Dr.1 Driver "There's a Hun in the sun!"

My version is a bit more upmarket than yours then. I made a metal plate (table) which is fitted to the jig saw when I want a band saw. I can clamp a straight edge to the plate(table) and use it as a rip-fence (is that the term?) for accurately cutting stuff. It helps secure the thing in place when mounting the jig/band saw upside down in tne workmate.

Perhaps I went a bit OTT ? >:-)

Reg

I would wonder just how many cut-off disc's one would go through cutting .250" 6061-T6 at, what Jim, 6" or 8" on each side of the gear???

Better have stock in Dremel!!

Bob

More than 3 for EACH SIDE!! .250" thick 6061-T6 Aluminum...not music wire!

Exactly!! The only band saw I have is for cutting wood and the blade is way too fast!!

I'll go along with that...

I cut ally on my bandsaw on a regular basis... doesn't matter how hard the ally is, it's nowhere near as hard as the blade.

-- Philip Rawson

I have a pack of blades for thick (1/4 to 3/8) sheet metal as of 7 pm. At least 7 inches.

You can cut 6061 with any blade that will cut wood. As a machinist I used to cut this stuff using wood bandsaw blades, typically 1/4" blades with 4 teeth per inch. The blades lasted as long as they would have in wood. I regularly cut it using a tablesaw with a normal blade; carbide is faster but if it jams, the aluminum can pull the carbide teeth out of the blade. The secret is to use a blade that has a number of teeth that will put no more than three teeth in the cut at any instant; fine-tooth saws will only plug up and create a lot of heat. With the four-tooth blades in 1/4" 6061, there was a max of two teeth in the cut, and the blade speed was 3000 feet per minute, same as wood. Never any hassle.

Dan

Thank you for the education!