How To Cut Aluminum Angle
If you do use an abrasive blade or a grinder either toss the disc or keep it for aluminum. You dont give the leg dimensions so Ill use 34 x34.
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If the motor housing on your saw is open and could collect metal chips tape a piece of cloth over the openings to protect the motor windings and bearings while you cut the aluminum.

How to cut aluminum angle. Blade Manufacturing makes a hss blade with 200 teeth for cutting really thin aluminum say window screen track but for most material being cut a carbide blade with 8 teeth per diameter inch will do well 10x 80 tooth is a good example. To cut 45-degree angles using a miter box follow these simple steps. For cutting 116 thru 18 material use 10 teeth per diameter inch 10 x 100 tooth or a 12 x 120 teeth.
The metal material is going to be cut. Hold the angle grinder at a 45-degree angle towards your metal and turn it on. Secure your miter box on a flat level surface.
Good qualitylong power cable. The ideal TPI for cutting thick aluminum plate is 10-14. At a moderate feed rate cut through the 1 by and the aluminum.
I used a non ferrous metal cutting blade that I g. For cutting metal with an angle grinder you need a thin disc like the 10mm cutting disc If you need a disc for long term use you can request a zip cut blade. The designation for teeth spacing is TPI Teeth Per Inch.
To do this job you need to have essential equipment which helps the user in many ways. There is a complete process of cutting metal with an angle grinder. Keep the wheel at a 90 degree angle for the entire cut.
Once you have all the tools set and ready in place it is time to prepare the angle grinder for the cutting process. Position the cutting wheel at a 90 degree angle to your cut mark. Exact size metal disc.
You dont need to apply much pressure. Grinders leave sparks that can burn paint and also leave a dangerously sharp edge. Primarily the equipment used are listed below.
A clampC-clamp that holds the metal. Do not add pressure or try to force the angle grinder through the material. Bring the cutting wheel into contact with the metal and allow the weight of the angle grinder to do the work.
Making accurate cuts on aluminum rods tubes and angles is easy with a miter saw and a blade designed to cut nonferrous metal check the label. This is a quick video showing how I cut some aluminum angle strips with a Dewalt DW713 compound miter saw. The zip cut blade is fiber-reinforced which means it is very durable and effective so you dont have to worry about damages to your disc.
In terms of blades youll want to make sure that you have something with a lot of space between the teeth. The noise made cutting 2 inch aluminum pipe with a radial arm saw is most impressive - the pipe works as a resonator. The blade that came with the saw will work fine.
Clamp the metal put a bit of wax on the blade cut slowly. Flip the safety off and turn your angle grinder on. Set the aluminum on a piece of 1 by so one of he legs is pinched between the 1 by and the fence on the miter saw.
Its advisable to use a clamp. Metal roofs are so thin that much safer and faster tools can get the job done. That is done by attaching the appropriate metal cutoff disc and putting the spindle nut in the right place.
Cutting metal roofs with an angle grinder It is not recommended to cut metal roofs with an electric angle grinder or a cordless angle grinder. Technically anything will eventually get through the plate but this is where youll see the best performance. Also unless the angle grinder that you are using is cordless this is.
Wait for it to reach full power and then press it against the area where you want to start your cut.
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