Best Tool for Cutting Aluminum Rod

I have an application coming up that will require cutting 3/4" aluminum rods, and I'm wondering what the most suitable tool might be. The rods will each be upright in an approximately 12" diameter hole in the ground, and I need to cut them off a few inches below ground level. The cuts don't have to be pretty, but I'd like them not to be angled much. The upper 4' of the rods won't be supported, so I'll be using vice grips or similar to restrain them during the cutoff operation.

In the past I've used a hacksaw, but it's pretty tough slogging, and this time around I'll have about 30 or so to cut, so am searching for a solution that requires less elbow grease.

I tried an abrasive wheel in a die grinder, but it was pretty slow. Any better suggestions?

Thanks.

Reply to
Jim Frame
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Saws-all with wood cutting blade.

Reply to
Tom Gardner

Bolt cutters with end cutting jaws? Something like this

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John

Reply to
John

Ok---it's a 3/4" piece of Aluminum, in a 4 ft+ deep 12" diameter hole, and you want to cut it off several inches BELOW ground level?

Carbide tipped saw blades are available in diameters down to at least 2". Maybe a

3" blade mounted on a serious die grinder? Another possibility would be a pair of cable shears. Looks like a pair of pruners on steroids, used for large electrical cable. Depending on how far below grade your cut is, the angle may become too much.

If you had a LOT of them to do, a portable hydraulic cable shear might work. Not sure if you can get one down in a 6" radius hole. Runs off of a port-a-power pump.

Know anybody on the local fire department that wants to get a little exercise for their Jaws of Life shear?

Bill

Reply to
Bill Marrs

You want something like a die grinder fitted with a circular saw blade, a full blade guard, and some sort of rest to lean on the rod. An abasive wheel just clogs up in aluminum, look for a carbide toothed blade.

You might want to check out the battery powered circular saws with the

4" or so blades.

Jim Frame wrote:

Reply to
RoyJ
1.Melt them off with an O/A cutting torch?

  1. Skilsaw, mabye one of those with a 4 inch diammeter blade, if there's room.

  2. Cut them off above ground with the most convenient method, then bend them with a big hammer until they are far enough below ground.

Pete Stanaitis

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Jim Frame wrote:

Reply to
spaco

Doesn't sound like fun. I would suggest a Saws-all with a flexible blade a few inches long. Drop a big washer or drilled plate over the rod and let the blade slide on this as you cut. IOW, the saw is at an angle, but the blade is cutting horizontally. If you come in from several directions, you may be able to break the rod by flexing it.

Reply to
Leo Lichtman

On Mon, 02 Jul 2007 07:24:46 -0700, with neither quill nor qualm, Jim Frame quickly quoth:

How about a Lancelot blade on an angle grinder?

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Is your aluminum alloy one which this would cut well?

- Metaphors Be With You -

Reply to
Larry Jaques

"Tom Gardner" wrote in news:i%7ii.43058$ snipped-for-privacy@newssvr21.news.prodigy.net:

Second that motion. Use an 8 or 10 TPI blade. Will be quick work.

Reply to
Anthony

Electricians hydraulic cable cutters would make short work of that bar.

John

Reply to
John

I neglected to mention that the cut end of the rod has to remain round so that a cap can be friction-fit onto it. That pretty much precludes the suggestions that involved bolt cutters and the like, which would deform the rod. I don't want to have to reshape the ends any more than I want to hacksaw them.

I'm going to try the Sawzall suggestion and see how it works. If not, I may be back for more ideas!

Thanks to all who responded.

Reply to
Jim Frame

How about a home made shear? Couple inline holes in two blocks of steel hinged side by side, one bolted to the bench, the other to a long handle.

Stick the rod through both holes, and pull. Pink! Off it comes

Gunner

A human being should be able to change a diaper, plan an invasion, butcher a hog, conn a ship, design a building, write a sonnet, balance accounts, build a wall, set a bone, comfort the dying, take orders, give orders, cooperate, act alone, solve equations, analyze a new problem, pitch manure, program a computer, cook a tasty meal, fight efficiently, die gallantly. Specialization is for insects. Lazarus Long

Reply to
Gunner

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