Cutting/trimming aluminum

Discuss Cutting/trimming aluminum in the SNOWMOBILE RELATED DISCUSSIONS AND RIDING AREA's forums; Whats the best tool for cutting/trimming aluminum? I'm installing a drop and roll kit on my 04 and I'm sure ...


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Old 08-21-2008, 11:44 AM   #1 (permalink)
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Cutting/trimming aluminum

Whats the best tool for cutting/trimming aluminum? I'm installing a drop and roll kit on my 04 and I'm sure there will be some trimming involved. I have a grinder with zip cuts for the easier areas but what works best in tight spots.
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Old 08-21-2008, 01:40 PM   #2 (permalink)
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Re: Cutting/trimming aluminum

Air Body Saw with lots of wax on blade. Milwakee general purpose metal blade, go slow and use wax every 6 inches. Other blades cut faster but this combo gives you best control and clean edges.......Bolt Supply House has every thing you need
Or a plasma cutter if you can get the torch head in there.......If useing a plasma un hook batteries and electronic modules to be safe.
Be sure to use wheels made for alluminum.....ordinary ones will glaze ..... be hard to control...and increase heat...and cause destortion.
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Old 08-21-2008, 06:40 PM   #3 (permalink)
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Re: Cutting/trimming aluminum

Thanks snotrocket, went out and found one for $50, works great. Now I just need the kit from specialty to get here.
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Old 08-21-2008, 06:50 PM   #4 (permalink)
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Re: Cutting/trimming aluminum

Originally Posted by xtremegriz View Post
Thanks snotrocket, went out and found one for $50, works great. Now I just need the kit from specialty to get here.
Just remember to use the wax...like night and day.
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Old 08-23-2008, 06:00 AM   #5 (permalink)
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Re: Cutting/trimming aluminum

Originally Posted by xtremegriz View Post
Whats the best tool for cutting/trimming aluminum? I'm installing a drop and roll kit on my 04 and I'm sure there will be some trimming involved. I have a grinder with zip cuts for the easier areas but what works best in tight spots.
If you use a zip cut disk(or any steel disk) on aluminum, throw it out when you are done. If you use them on steel afterwards, the aluminum melts on the disk and can cause it to disintegrate.
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Old 08-23-2008, 11:46 AM   #6 (permalink)
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Re: Cutting/trimming aluminum

Originally Posted by snotrocket View Post
Air Body Saw with lots of wax on blade....
What he ^^^ said X2.

Princess Auto has the air body saws on sale right now - right around $30.
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Old 08-24-2008, 12:51 PM   #7 (permalink)
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Re: Cutting/trimming aluminum

Thanks for the tips guys, Got her done last night, just waiting on a new axle for the Big wheel kit. The Drop and Roll kit from Specialty is pretty straight forward and now I can't wait to try it out. Heres some pics of the process.
Attached Images
File Type: jpg D&R1.jpg (74.9 KB, 7 views)
File Type: jpg Drop &Roll 002 (Medium).jpg (68.9 KB, 5 views)
File Type: jpg Drop &Roll 004 (Medium).jpg (68.3 KB, 3 views)
File Type: jpg Drop &Roll 005 (Medium).jpg (65.7 KB, 4 views)
File Type: jpg Drop &Roll 006 (Medium).jpg (61.9 KB, 3 views)
File Type: jpg Drop &Roll 008 (Medium).jpg (54.2 KB, 4 views)
File Type: jpg Drop &Roll 010 (Medium).jpg (72.1 KB, 4 views)
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Old 08-24-2008, 12:53 PM   #8 (permalink)
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Re: Cutting/trimming aluminum

One more pic
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File Type: jpg Drop &Roll 014 (Medium).jpg (74.0 KB, 5 views)
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Old 08-24-2008, 10:33 PM   #9 (permalink)
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Re: Cutting/trimming aluminum

Looks good.I also use an air powered hacksaw with good results.
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Old 08-25-2008, 10:45 AM   #10 (permalink)
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Re: Cutting/trimming aluminum

Originally Posted by snotrocket View Post
Just remember to use the wax...like night and day.
Please don't tell us you use left over wax on your legs!!!!!!

(couldn't resist)
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Old 08-25-2008, 12:46 PM   #11 (permalink)
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Re: Cutting/trimming aluminum

Originally Posted by imdoo'n View Post
Please don't tell us you use left over wax on your legs!!!!!!

(couldn't resist)
I use the left over wax for my BUG EYES
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Old 08-26-2008, 02:43 PM   #12 (permalink)
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Re: Cutting/trimming aluminum

How far back is the D&R?

Looks like about 2" down and 1/2" back? Bigger track?
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