Cutting Aluminium
Printed From: The Fishing Website
Category: General Forums
Forum Name: The Boat Shed
Forum Description: Discuss all things boating.
URL: https://www.fishing.net.nz/forum/forum_posts.asp?TID=98712
Printed Date: 15 Jun 2026 at 1:45pm
Topic: Cutting Aluminium
Posted By: Nathan
Subject: Cutting Aluminium
Date Posted: 12 Feb 2014 at 11:49am
| I need to cut a hole in the dash to fit a vhf. Whats the best way to cut the aluminium to get a nice neat cut. Wondering if my multi tool would do it with the metal blade. Any advice appreciated. Cheers. |
Replies:
Posted By: flyfisher
Date Posted: 12 Feb 2014 at 12:02pm
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I've done this dozens of times. I always take the cheap route, have had good success, just drilling holes close together with a good bit, pushing it out and using a combination of round file / flat file and diamond grinder on a high speed drill to smooth it out, it works and is accurate. The Dremel will not have enough grunt, they stall and cut out under pressure, but okay for fine detailing. But for a rectangle cut-out, if you can get a jigsaw (with a fine metal blade) into the flat planes of the cut-out, this will work well if you use a big bit to drill out the corners as well to fit the blade (10mm). It's noisy and messy work though, but strangely fun! Just have to make sure you won't 'nick' anything behind where you are cutting. Most flush mounts allow for a small amount of error either side of the template, so does not have to be perfect. I find aluminium clogs the teeth of domestic metal blades real easy, almost fuses to it, so usually use a few for such a job, think the commercial ones are better but more $$$. ------------- https://www.youtube.com/user/troutboynz |
Posted By: Otto
Date Posted: 12 Feb 2014 at 12:12pm
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If using a jig-saw don't use to fine a blade for clogging reasons. Also place masking tape or similar on the foot of the jig-saw, helps to stop it marking your dash. Ideally also put tape around the hole you are cutting out for the same reason. |
Posted By: Blindspot
Date Posted: 12 Feb 2014 at 12:28pm
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I am told a hole saw works quite well. Use low RPM and a few squirts of wd40 as you drill. ------------- http://www.legasea.co.nz" rel="nofollow"> 
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Posted By: Time_Bandit
Date Posted: 12 Feb 2014 at 1:43pm
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I drill holes in all four corners then use a 4' grinder with a Aluminium cutting disc on it ------------- “Be yourself; everyone else is already taken.” |
Posted By: Blindspot
Date Posted: 12 Feb 2014 at 1:58pm
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oops didn't read what he was mounting and assumes it was guages ------------- http://www.legasea.co.nz" rel="nofollow">
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Posted By: billyhill
Date Posted: 12 Feb 2014 at 2:02pm
| When your cutting or grinding aluminium put some hand cleaner on the metal first, it stops the blade or disc from clogging and washes of with water afterwards.Be carefull if your using a grinding disc though as this trick works so well its really easy to take to much ally of the workpiece.You would be amazed how much quicker you can cut using a hacksaw too. |
Posted By: Spearsniper
Date Posted: 12 Feb 2014 at 5:42pm
+1 And putting tape around the boundary of what you are cutting gives to a nice line to follow when cutting. |
Otto wrote:Posted By: Spectrum
Date Posted: 12 Feb 2014 at 9:17pm
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fastest cleanest most dangerous way is to us a hole saw. use a good drill with variable speed set to low and a solid right angle handle stand with a good stance and hold on like hell. when you start angle the bit so only one corner cuts then as you get it cutting straiten it up. a few squirts with water will help keep it cool and clear the hole saw good luck
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Posted By: Spearsniper
Date Posted: 12 Feb 2014 at 9:23pm
| ^ not sure a holesaw will work to cut a rectangular hole. |
Posted By: lemmy
Date Posted: 12 Feb 2014 at 9:36pm
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Meat Axe blade on a 4" grinder was one of the scariest tools I,ve ever used while building Superyachts but cuts Alloy like a hot knife through Butter. |
Posted By: Steps
Date Posted: 13 Feb 2014 at 8:37am
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Old school. 4" grinder with cutting disc..... lay masking tape along the line. Start a little inside , in the middle and take your time.. work to each end. The verticals are short therefore cant get a full depth cut.. but whats left in each cnr is easy finished with a hacksaw. Finish dags off with a file And radios and the like have a lip that goes beyond the hole edges Modern method: As per the original post question.. those new fandged electric utility muti tools that one sees on all the TV displays in the hardware stores....simple easy and quick...but the elcheapo brands the cutting tools are made of crap steels. cutting/ milling Aluminum use kero as the cutting fluid |
Posted By: MikeAqua
Date Posted: 13 Feb 2014 at 9:14am
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Tape up as others have said. Hole saw or drill in each corner - sized to suit to the corners of the VHF. Cut the straight lines between with one of the tools suggested above. Multi tool should be fine if you can get it to cut nice and straight. Mine likes to wander off on an angle. Grinders are OK but can be a bit kicky. Personally I would use a jigsaw or a cutting blade on a dremel. Both are slow, but small, precise and easily controlled. If you have mounting screws or similar, use duralac between the screws and the alloy. This discourages the alloy from corroding where it contacts the stainless. |
Posted By: Kevin.S
Date Posted: 13 Feb 2014 at 9:37am
You could just drill a hole in each corner and use something like this It won't be quite as quick as an angle grinder, but aluminium is pretty soft and easy to cut and there is no danger of slipping and wrecking your dashboard.
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Posted By: Dead Ant
Date Posted: 13 Feb 2014 at 7:07pm
| If you are covering the screws with covers then you can use nylon screws and nuts to avoid disimiliar metals. |
Posted By: MikeAqua
Date Posted: 14 Feb 2014 at 11:04am
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Thanks for the post on nylon screws Dead Ant. I had no idea they existed. Perfect for securing lightweight things. I can think of about a dozen sets of screws I'll be replacing on my boat with them. |
Posted By: Dead Ant
Date Posted: 14 Feb 2014 at 8:22pm
| Try Hi-Q components on the shore for the nylon stuff. They have a good website, are really helpful and have stock. I like dealing with good buggers :) http://www.hiq.co.nz" rel="nofollow - http://www.hiq.co.nz |