Making aluminum washers out of 1/8 inch 5052 plate

[Antoine]

Has anyone tried to use a hole cutting drill on aluminum 1/8 plate. I thought that would be the easiest way to make a large washer. Any suggestions?

 

[chevyrulz]

Antoine » Today, 08:48[/url]"]Has anyone tried to use a hole cutting drill on aluminum 1/8 plate. I thought that would be the easiest way to make a large washer. Any suggestions?

a hole saw will cut through it. the blades will last much longer if you keep them wet w/ oil & go slowly. heat eats the blades & hole saws ain't cheap. you'll probably have a lot of cleanup work w/ the file or grinder to make smooth washers

 

[cva34]

hole saw make nice round clean up with coarse file.....saber saw cut round an clean up with coarse file... saber saw cut square...cut square with hack saw round with coarse file ...I know it sounds stupid... but if you got a double insulated saw or drill and gfi..dripping a few drop of water on cut cools blade and keeps chips from building up..and of course any cordless would be no problem

 

[JMichael]

Or you could take some large round stock, drill a hole down the center, then cut your washers to desired thickness with a power hack saw or portaband.

 

[Antoine]

I used a 2 inch hole saw then touched them up with a 4 inch grinder a sanding pad. I put them in today with the G-Flex. It worked great, I hope that took care of the leak.