Aluminum plate fabrication?

[06RTCharger]

Has anyone worked with thick aluminum sheet/plates, like 1/4-1/2 thick. Can hand tools be used? Like a jig saw, circular saw, router, stuff like that. Is it possible to fabricate and shape the aluminum like you would with MDF?

[Jessica]

only time i used it it was 1/2" X 2" flat bar, I used a power band saw and then an angle grinder with a flap wheel. Drilling is easy as pie and so is tapping threads. It's pretty soft metal though so shaping it shouldnt be too bad.

[06RTCharger]

whats the flap wheel do, polish/smooth it out?

[WalledSonic]

I used a drill, router, and miter saw to create a tricky-shaped copper bus bar.  I wouldnt use the router again like that, its really bad on the bearings.  Its also dangerous.  Here's the link where I show the build process step-by-step (comment 78 in my build log if this link doesnt work).  Copper is denser than aluminum, so you should have less trouble.  THIS IS NOT THE BEST WAY TO GET THE JOB DONE, its just what I had at the time.  I would get a small mill if you plan to do this stuff more often.

 

[06RTCharger]

You free handed with the router?? I noticed the copper plate was clamped in the vise. How thick was that copper, looks almost 3/4-1in. Came out nice too. You gotta take very very small passes each time right, just barely taking shavings off each pass. Thanks for the help man.