Slicing Aluminum Like Butter

Rick was out tonight, at a late business meeting, so I was on my own. My assignment: prepare a replacement panel to cover the hole left when we took the furnace out two years ago. Since then, we’ve covered the hole up with plastic–which isn’t really a roadworthy solution.

Today, I used a new tool (electric metal shears from Harbor Freight) and cut out a panel to fit. The job wasn’t tough, but I was working with new, expensive materials (T3 aluminum) and an unfamiliar power tool. My earlier experiences with fabricating aluminum wasn’t positive–using tin snips I got jagged edges and had trouble manipulating the metal on inward curves. I had none of that trouble today–I just followed the line and the shears just plowed into the metal. Pretty darn cool!

This aluminum is a lot thicker than I thought, but it cuts up nice. I achieved fairly smooth cuts, but I want to sand it to remove a little waviness in my line and to possibly round off the edges. I’m going to need a new sanding belt to do that, though. This task is pretty easy and fun! I may just get hooked on fabrication after all!