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post #1 of (permalink) Old 07-03-2002, 12:52 PM Thread Starter
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best way to cut aluminum diamond plate?

I've got some aluminum diamond plate corners that I want to use to mount up some round LED tail lights. I've only done some minor work with aluminum before and couldn't get it very clean as compared to steel. Any ideas on the best way to trim and cut circles in this stuff cleanly?
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post #2 of (permalink) Old 07-03-2002, 01:14 PM
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Re: best way to cut aluminum diamond plate?

For my LED tailights I used a hole saw, I have also cut them with jigsaw and air saw with metal blades.
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post #3 of (permalink) Old 07-03-2002, 06:22 PM
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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.
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post #4 of (permalink) Old 07-03-2002, 06:33 PM
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Re: best way to cut aluminum diamond plate?

I've also heard about putting some bar soap on the blade of whatever you're using to cut. Aluminum is real soft, and clogs up the blade easily.
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