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I just got through cutting up 3 4'x12' sheets of 1/8" aluminum. I used my Skilsaw with a carbide blade for the straight cuts and my DeWalt jigsaw for the curves. One problem you may have is if your aluminum is a special alloy that would make it hard or brittle. The general purpose aluminum is easy to cut with a medium wood blade or a coarse metal blade. Both worked for me.
-------------------- John Smith Kings Bay Signs (Retired) Kissimmee, Florida Posts: 822 | From: Central Florida - The Sunshine State | Registered: Jan 2000
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Dewalt makes a blade that does an incredible job on aluminum. Part # DW3705H. If you can follow the line, there will be very little to clean up.
-------------------- Dave Johnson Saltsburg, PA
724-459-7240 Posts: 228 | From: Saltsburg, PA | Registered: Dec 2001
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A good router and wd40, as CJ says. Use a template if at all possible. Shep'
-------------------- Arvil Shep' Shepherd Art by Shep' -------- " Those who dance are thought to be mad by those who cannot hear the music " Posts: 1281 | From: Mt Airy NC | Registered: Mar 2001
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As far as the welding goes I learned the hard way to through my rr job. Exposed skin equals burnt skin as in sun burnt.
-------------------- Ricky Simpson Simpson Signs South Central VA, USA "railroader aspiring to be fulltime SignArtist." Posts: 246 | From: VA | Registered: Jan 2000
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