Join Date: Dec 2001
Location: Belleville, Illinois
Thanked 22 Times in 17 Posts
Re: best way to cut aluminum diamond plate?
A hole saw is your best bet.
Get one with big teeth. Use plenty of cutting fluid and turn the tool slowly. Checker plate is usually dead soft. As such, the chips will load up the teeth. The cutting oil helps prevent that, as does backing the tool out every few seconds and blowing or bruishing the teeth clean.
Another good trick is to drill the pilot hole with a regular 1/4" bit, and put a piece of plain 1/4" rod in the hole saw arbor as a guide instead of using the drill bit they supply. Plain rod is a little stiffer, and won't enlarge the hole as a drill bit can. If you can get a piece of 1/4" drill rod to use, that is better yet.