Whats the best way to cut the aluminum on your tunnel/boards ?

[christopher]

So, the time has come to remove the boards from my Nytro in preparation to install the new tubular set I got from Skinz.

I need to cut the existing boards off leaving a 0.75 inch flange along the bottom where the new ones will rest on and be riveted to.

My question is, what is the best route to make this cut.?

Which tool would do the best job at slicing off the existing aluminum?

 

[smokindave]

I always use a angle grinder with a cutting disk,just mark your lines well and have at her and the use a grinding disk to clean up the edges afterwards.
I have tried a few other ways but found this to be the quickest.

 

[MARV1]

Oxy-acetalene torch with fine tip and a steady hand works best on Yammi's.

 

[christopher]

Oxy-acetalene torch with fine tip and a steady hand works best on Yammi's.

Geeez.
That seems a bit much, considering I have never handled a torch in my life.

 

[christopher]

I always use a angle grinder with a cutting disk,just mark your lines well and have at her and the use a grinding disk to clean up the edges afterwards.
I have tried a few other ways but found this to be the quickest.

You think this is superior to a little air saw??

 

[MARV1]

All kidding aside, just bring it to a shop, you'll just screw it up even if we'd tell you and show you how to do it. Look at how this forum is getting screwed up, look at how you screwed up your SAR adventure last winter!

 

[smokindave]

You think this is superior to a little air saw??

That will work just fine as long as you have a compressor that stores enough air and can build enough air to run it.
When I did some tunnel cutting last season I bought a couple of different air grinders,I got a angle grinder and a straight grinder.
What worked best for me though was the old electric angle grinder and a good set of tin snips.
Its a bit unnerving cutting a perfectly good tunnel but all should work out just fine as long as your measurements are good.
I would make your cuts where you need them the first time as just trimming a small amount off can be a pain as the smaller the cut the more it vibrates.
A plasma cutter would work excellent if you have one or can afford one for a one time use.

 

[Jkinzer]

plasma cutter is the fastest and easiest way, if you dont have access to one then i'd use and angle grinder with a cut off wheel, that air saw would probably work alright too

 

[newmy1]

Long summer.....

All kidding aside, just bring it to a shop, you'll just screw it up even if we'd tell you and show you how to do it. Look at how this forum is getting screwed up, look at how you screwed up your SAR adventure last winter!

 

[milehighassassin]

I have always used a sawzall with a fine blade.

 

[m8magicandmystery]

I have always used a sawzall with a fine blade.

x2...sawzall...good jig saw..all you need..often works better cutting from the bottom verses the top..hand file smoothes the edges afterwards

 

[Wheel House Motorsports]

I always rock the sawzall.. but its just what I have, but it works, and there sorta are some tricks.

I forgot the tooth spacing on the ones I use, but they are the wider tooth spacing for the size of alum I am cutting, reason being is I find that fine tooth ones just clog up and stop working and need to be delt with. Also, dont push to hard as it has a tendency to get really hot and start to gum up even faster.

Did I really just give instructions on how to properly use a sawzall"?? thats bad, pretty much throw a big arse blade on it and kick some ***!!

 

[snowmobiler]

since theres no way to freehand a perfect straight cut with a sawzall,id use 3/4 wood against the tunnel or something for a guide.

 

[pylon]

an aluminum specific cut off wheel on a electric grinder works the best . normal cut off wheels are not abrasive enough and will ball up with aluminum making them jumpy . they make it really nice to cut a strait line .

 

[christopher]

This is one of those things I don't get to do a 2nd time, so I want to make sure it gets done right the first time around.

Right now I don't have air.
So if I go the air route, then I will have to buy a compressor as well.

The plasma cutter would be awesome, but I don't have one and can't justify buying one for such a small project.

The grinder is looking good to me right now.

 

[christopher]

All kidding aside, just bring it to a shop, you'll just screw it up even if we'd tell you and show you how to do it. Look at how this forum is getting screwed up, look at how you screwed up your SAR adventure last winter!

Hope you won't be offended by my not taking your suggestion here.

I learn by doing.

I learned ALOT from my misadventure last spring.

I will learn even more from all the mods I am doing this summer.

 

[christopher]

an aluminum specific cut off wheel on a electric grinder works the best . normal cut off wheels are not abrasive enough and will ball up with aluminum making them jumpy . they make it really nice to cut a strait line .

Any SPECIFIC suggestions ???

 

[Ten-Zing]

Fact is a jigsaw with a metal cutting blade approaching from the bottom of the running board is the best way. If your real serious about it being perfectly straight then remove the rear skid and put up a fence that you can clamp to the bottom of the running board and put the guideplate from the jigsaw against it.

A cutting wheel will cut aluminum. And it will make the job quick, but a fenced jigsaw is a less ghetto way of getting the cut right.

 

[KSH]

Any SPECIFIC suggestions ???

When you go to your supply store, the disc's will be marked for what metal they are designed for.

Buy a large air compressor, you'll never regret it.

I used a Air sazall on my projects.

 

[m8magicandmystery]

SHAME ON YOU...!!!!!..lol..