Cutting the rails

[jnesmith]

Hello everyone:

I recently purchased the wide table kit, but really only want and need half of the additional capacity of the add-on rails.

For those that have cut the rails, how did you do it? Miter saw? Do you need a special blade? Any other considerations?

Thanks.

John

[Black wallnut]

Please do not ask me how I know but carbide sawblades easily cut the aluminum extrusions on your saw.

Keep in mind you will have silver tinsel all over the place. Wear suitable eye protection.

[LCHIEN]

woodworking blade will do a fine job on aluminum without undue wear on the blades.
A 50 or 60 or 80 tooth would be my preference. Use DC or VAC if you can or there will be aluminum chips all over the place.

You could also hack saw it and clean up with a file. But the table saw/miter saw will be much prettier.

[LarryG]

In addition to eye protection, a shirt with long sleeves (close fitting, though: nothing too baggy that will create a different kind of safety hazard) is a good idea. That aluminum tinsel Mark mentions is HOT.

Also be sure to clamp down the rail securely. I have found that when cutting aluminum extrusions, they have a tendency to self-feed laterally, thus producing cuts that aren't perfectly square.

[jnesmith]

Good info.

Thanks everyone.

[RodKirby]

Way back , when I cut my rails, I invested in a (Cheap), CMS that I dedicated for cutting Aluminum. AND got a "non-ferrous" negative rake blade (cost more than the saw ). One of my better investments - used often

[gsmittle]

In addition to eye protection, a shirt with long sleeves (close fitting, though: nothing too baggy that will create a different kind of safety hazard) is a good idea. That aluminum tinsel Mark mentions is HOT.

Remember to button the top button on the shirt, too, so the hot tinsel doesn't go down. DAMHIKT.

g.

[Pappy]

The few times I have cut aluminim on the miter saw or table saw I cleaned up the cut n a disc sander. Leaves you with a very smooth finish on the cut.

[yamato72]

In addition to eye protection, a shirt with long sleeves (close fitting, though: nothing too baggy that will create a different kind of safety hazard) is a good idea. That aluminum tinsel Mark mentions is HOT.

Also be sure to clamp down the rail securely. I have found that when cutting aluminum extrusions, they have a tendency to self-feed laterally, thus producing cuts that aren't perfectly square.

+1

The standard carbide-tipped cut-off blade that came with my compound miter saw worked perfectly. Clamp it tightly and use protection.

[dbhost]

My 10" non sliding CMS is now dedicated to cutting non wood. It presently has a Diablo D1084L which Freud recommends for non ferrous metals, laminates etc... It cuts super smooth... Even with the OEM B&D 40T blade it left a good finish, and didn't even think of dulling the blade...