I am looking for some recommendations, please.
I want to cut sheet aluminium - thin stuff, straight line cuts. For use on hobby projects. What's the best tool for this? A table saw?
I am on a student budget so cheaper is better, but I am also not looking to cut my fingers off so safety is important too.
As someone who deals in sheet metal a lot, don't use a jigsaw. And not scissors either unless it's really thin (like 0.5mm or less). What you are talking about is "tin snips", and they are only good for cutting through or shaping small sections, not long lines.
What op wants if it is bigger sheets is either a sheet metal nibbler or a grinder with a cut off wheel. Ideally what they want is a plasma cutter. A plasma cutter will do everything. Long lines, whole sheets, shapes, etc. Downside is, molten metal and need a good area to cut it in.
I find cut off wheels jam too much in Al and find a jigsaw much quicker and neater. Agree that a nibbler is great but use that more for curves. Never used a plasma cutter.
(I am not a full-time professional metal worker but do plenty of my own maintenance and prototypes with sheet metals.)
Oh, should not be using cut off discs on Aluminium. On steel sheeting, it's fine, but should never use grinding wheels on Al. I might use a jigsaw on thicker aluminium, but not on thin sheet.
And nibblers are ok for straight lines if you use them against a straight edge, but yes, they take a bit of skill to use well… and are noisy af.
The best part of plasma is that they cut any metal. So if OP was to be making "art" and wanted to cut copper, aluminium, stainless, gal sheet, etc, a plasma will do all of them. It's basically a much neater and easier to use version of what an oxy/acetylene touch would do.
Ideally, a guillotine is what is best, but unless you are doing bigger sheets and/or heaps of them, it can take up too much space. Benefit is long straight cuts and virtually noiseless.
an angle grinder cuts sheet metal perfectly. In regards to keeping it straight, you'll need to mark where you want to cut and use you hands/eyes to keep it in line
Do you have a drill?
if so, I have had one of these for 15+ years. It has been excellent.
https://www.irwin.com.au/tools/drill-bits/falcon-nibbler
Pros;
no sparks from cutting discs
no sharp edges
safe in regards to cutting fingers etc
Cons;
Will need to set a straight edge to run it along if a perfect straight line is the goal
Can be tricky cutting across corrugated iron
Dremel or a similar rotary tool for even cheaper; e.g.:
https://www.bunnings.com.au/ozito-home-12v-rotary-tool-skin-…
How thick aluminium are you taking about?
I have fabricated 1mm cladded dildo benches for clients in the past. Had to tig weld the edges and grind down to avoid cuts.
It’s best to use tin shears or even a solid pair of scissors. You need special cutters for aluminium as it is quite ductile and contaminates cutting edges quickly.
I just had to search what are "cladded dildo benches"
not helpful
.
It’s really nothing special. Just a 9 shoulder wide bench about squatting height. The aluminium was to facilitate sturdy dildo suction and easy wipe downs I’d imagine. They used it for sex shows
Username checks out.
@ssquid: I came here thinking it was an industry jargon word for a special type of bench, say, like a hot dog bun type of thing…
Nope, literally a "dildo bench"…
Every day is a school day
how thick?
I use something like these (different brand though) and they work up to 1.5mm.
https://www.bunnings.com.au/irwin-straight-cut-aviation-snip…
Beyond 1.5mm I use a cheap Jigsaw with a fine metal cutting blade. You'll get a pendulum Ozito for $40. A pack of 5 blades will be $12+.
You'll need some files or flapper discs to dress the edges
Depending on how clean a cut edge you require, a strong piece of wire and a handle of some description works like a charm - How to Cut Sheet Metal with Baling Wire. You can also anchor the end to a star picket driven into the ground and ditch the timber guide, just keep your feet close together and close to the point being cut.
Usually very easy. Jigsaw, even a pair of really good scissors or snips for stuff thinner than 1mm.