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post #1 of 11 Old 08-27-2013 Thread Starter
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Cutting an aluminum boom

I have an old boom that came off a Catalina 27'. It got bent and is no longer usable as boom and the boat is long gone anyway.

It is good aluminum however and I could use a couple short pieces for a project I have in mind.
I have a chop (miter) saw that is big enough.

Is their any kind of blade I can put in the chop saw so I can accurately and squarely cut the aluminum extrusion.
If so is their anything I should know other than wear hand and eye protection and go slow.

I'm very comfortable with any kind of wood work but my metal working experience is limited.

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post #2 of 11 Old 08-27-2013
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Re: Cutting an aluminum boom

A 60 tooth blade will make a nice cut. I did a 9" mast section this way.
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post #3 of 11 Old 08-27-2013
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Re: Cutting an aluminum boom

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A 60 tooth blade will make a nice cut. I did a 9" mast section this way.
I use the above and some cutting oil to make the blade stay sharp longer.

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post #4 of 11 Old 08-27-2013
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Re: Cutting an aluminum boom

And if you want to save your nice 60 tooth blade for wood they do make "cut off wheels" for aluminum. A good 60 tooth saw blade is not cheap.
ALUMINATOR Cut Off Wheels for Aluminum | Rex-Cut Abrasives
No affiliation.
Home despot probably carries an equivalent product.

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Re: Cutting an aluminum boom

Wax candle help the cut and prevents spauling on the teeth. Otherwise just like wood.
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post #6 of 11 Old 08-27-2013
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Re: Cutting an aluminum boom

What is it with Catalina 27s & 30s with the bent booms?
Is it the mid boom sheeting?
A Catalina 30 at our club bent it's boom while racing in 20+ knots a few years ago; accidental jibe.

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post #7 of 11 Old 08-27-2013 Thread Starter
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Re: Cutting an aluminum boom

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What is it with Catalina 27s & 30s with the bent booms?
Is it the mid boom sheeting?
A Catalina 30 at our club bent it's boom while racing in 20+ knots a few years ago; accidental jibe.
In our case the OP had re-rigged the sheet from a three point connection to a single connection and we didn't know enough at the time to fix it.

It was already bent a little so was guaranteed to fold.
We just didn't know enough at the time.

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It is a lesson about the limitations of wax as an adhesive.
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post #8 of 11 Old 08-27-2013 Thread Starter
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Re: Cutting an aluminum boom

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Wax candle help the cut and prevents spauling on the teeth. Otherwise just like wood.
How do you do that exactly.
Rub it on the teeth before each cut?

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post #9 of 11 Old 08-27-2013 Thread Starter
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Re: Cutting an aluminum boom

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And if you want to save your nice 60 tooth blade for wood they do make "cut off wheels" for aluminum. A good 60 tooth saw blade is not cheap.
ALUMINATOR Cut Off Wheels for Aluminum | Rex-Cut Abrasives
No affiliation.
Home despot probably carries an equivalent product.
That looks perfect. I would prefer to use the miter saw rather than the angle grinder to get a better cut.
I see if I can get a wheel that will work on the bigger saw.

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It is a lesson about the limitations of wax as an adhesive.
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post #10 of 11 Old 08-28-2013
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Re: Cutting an aluminum boom

they make the 14" aluminum cut off wheel for a metal cutting chopsaw

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