Cutting Aluminum Sheet with Carbide Blade?

[algale]

Here's what's being built: a reflector oven for (what else) a canoe camping trip. This sits in front of a fire and bakes bread, muffins, etc. Still needs its internal shelf and some legs.

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The aluminum, which is a little thicker than 1/16th, cut really well on the Shopsmith using a combination carbide blade. The angled cuts for the ends were done on an Incra 5000 sled. Easy peasy.

But bending the aluminum has been a bear! I had to go buy a metal brake from Harbor Freight and I'll probably never use it again. I could have bought a professionally made reflector oven for what I've got invested in the materials and tools. But where's the fun in that?

Racing the clock because I go on a 5 day canoe trip a week from this coming Monday and I'm determined to have some fresh baked goods.

[JPG]

Here's what's being built: a reflector oven for (what else) a canoe camping trip. This sits in front of a fire and bakes bread, muffins, etc. Still needs its internal shelf and some legs.

IMG_1F7027ADED80-1.jpeg

The aluminum, which is a little thicker than 1/16th, cut really well on the Shopsmith using a combination carbide blade. The angled cuts for the ends were done on an Incra 5000 sled. Easy peasy.

But bending the aluminum has been a bear! I had to go buy a metal break from Harbor Freight and I'll probably never use it again. I could have bought a professionally made reflector oven for what I've got invested in the materials and tools. But where's the fun in that?

Racing the clock because I go on a 5 day canoe trip a week from this coming Monday and I'm determined to have some fresh baked goods.

Make it watertight, add a tether, add heavy stuff on the 'bottom', and use it as a 'trailer' for the SBTN.........Good luck at the rapids!



P.S. two by fours a couple of c clamps and a well applied hammer against a well positioned 2x4 will also make them bends(works on steel).

[algale]

Here's what's being built: a reflector oven for (what else) a canoe camping trip. This sits in front of a fire and bakes bread, muffins, etc. Still needs its internal shelf and some legs.

IMG_1F7027ADED80-1.jpeg

The aluminum, which is a little thicker than 1/16th, cut really well on the Shopsmith using a combination carbide blade. The angled cuts for the ends were done on an Incra 5000 sled. Easy peasy.

But bending the aluminum has been a bear! I had to go buy a metal break from Harbor Freight and I'll probably never use it again. I could have bought a professionally made reflector oven for what I've got invested in the materials and tools. But where's the fun in that?

Racing the clock because I go on a 5 day canoe trip a week from this coming Monday and I'm determined to have some fresh baked goods.

Make it watertight, add a tether, add heavy stuff on the 'bottom', and use it as a 'trailer' for the SBTN.........Good luck at the rapids!



P.S. two by fours a couple of c clamps and a well applied hammer against a well positioned 2x4 will also make them bends(works on steel).

LoL! Watertight it definitely is not.

[Hobbyman2]

Looks good
Funny you mentioned a brake from HF , I have 4 windows and a small amount of fascia that need replaced , I thought about doing the same thing .

Wonder how many tools they sell that only get used once ?

[JPG]

Looks good
Funny you mentioned a brake from HF , I have 4 windows and a small amount of fascia that need replaced , I thought about doing the same thing .

Wonder how many tools they sell that only get used once ?

Probably quite a few! Some break before finishing task, some simply do not perform correctly, and some actually do what they are supposed to.

Actually makes sense if no future need is anticipated. Why spend much $ for a single use?

[JPG]

$15 cheaper???

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[algale]

Well it's done. Quick and a little dirty but should get the job done. For those who haven't used one, a cooking sheet or pie tin is placed on the shelf.

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[JPG]

Apparently the 'sun room' is still 'occupied'.

Sheet metal work is 'different' ain't it.

Ya gotterdone and will serve thee well I think. Keep those sharp edges off the SBTN finish!

Thank You for sharing(again).

[charlese]

Man! You continue to do stuff in SPADES! Congratulations on the build.

Did you look at renting a break?

[algale]

Man! You continue to do stuff in SPADES! Congratulations on the build.

Did you look at renting a break?

No, Charlese, I wasn't smart to think of going to the rent-a-center. I wish I had!

The Harbor Freight brake just wasn't up for the job. In fairness, I knew my aluminum sheet was at least one gauge thicker than the brake was rated for. But with some effort it handled the large, long gentle bends on the body of the oven.

But paradoxically, the short, sharp 3/4" 90 degree bends for the tabs on the side pieces and shelf it just couldn't handle. No matter how many C-clamps I applied, the work piece and the heavy metal piece that sits over the work piece just slid back.

I resorted to doing those bends in a metal vise and using brute force and a lot of hammering with a rubber mallet. All of which made for of lot of extra work to try to get things smooth and even and flat. Ultimately it worked out ok and I am reasonably pleased with the final result. But a bigger, better brake would have made the job MUCH easier.

The Shopsmith, however, performed flawlessly! If you ever need to cut aluminum, don't hesitate to use a Shopsmith carbide blade in table saw mode. I don't know what the maximum thickness is that it might handle, but it cut through 1/16th inch aluminum like nothing. Also used with great effect on this project was the Shopsmith band saw (to cut away corners on the tabs) and the belt sander on a few spots.

I've never riveted anything before. Used a Stanley pop-riveter and was surprised how simple that was to use.