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I use a band saw today but use to use a sabre saw years ago. Go slow with a scribed line not magic markered or something and I used WD40 to keep the blade clean. RM
 

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T/S 368E
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33,647 Posts
.

Band saw also, have used jig saw in the past. As mentioned, check teeth often, they get clogged easy.

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I use auto trans fluid on the blade... works well... also use it on carbide cutters to keep clean when working with alu..

or plazma cut

mike
 

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I make a wood template.Then Jigsaw close to template on low speed w/ cutting oil.Then clamp the aluminum and wood together and router the aluminum to your template.
This looks more professional than sanded edges IMO.....

Or CNC?
 

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winners circle
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5,556 Posts
i used a sawzall and a my brother air file to make it was straight and smooth.
 
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