Tip - Tape some sacrificial aluminum at the end of your cut. If your blade grabs and pulls near the end of the cut, you can end up with an ugly scar on your piece. The sacrificial aluminum will protect your part if this happens. You can also use a straight piece against the good side of your piece to protect and serve as a guide.

I had something similar where I needed to cut a hole for a clear polycarbonate window. Yes, I could have used a cut off wheel like you did, but I used a router attachment for my rotary tool with a general purpose cutting bit. Then I just set up some stops and routed out the hole. Worked great. Of course the way I did it requires a lot more setup and a larger workspace.

If you go back and forth with shallow cuts your cutoff wheel will last a lot longer rather than going deep. The latter "chunks out" the wheel and it wears rapidly. There's a test on YT somewhere. Think it's by Fireball Tool or similar. $0.02.

Very helpful, now I feel confident enough to give it a shot.

Tried it the other day, now I'm not allowed to go near the airport :/

Just what I was looking for. Making a race look foot plate for my racing scooter and needed to cut rectangles inside the footplate...was looking at wrong tools like electric metal sheets for my small project....plus I own a Dremel already.

I am trying to build a bearhawk, and I was wondering if I could the Dremel to clean up the wing parts that I have made so far. I can send you pix if you would like to see what I am talking about. The aluminum I'm working with is .025 and .032 for the Aileron, flap, pocket nose rib blanks

Very helpful info. Thank you

Awesome just what I needed to see before purchasing!

Thanks, I used this video to see if the dermal you used could cut metal

Thank you so much!

Thanks for the info,I order one.

I think this is David Lynch speaking.

I use an air nibbler. Super fast. Then I clean up with a carbide burr in a micro air die grinder. But everyone as their own way. This way here doesn't require a compressor

Why does this video end so abruptly?

Looking for ways to do the same but all curves.

Nice job. Do you think that tool would work on 1/4” aluminum as well?

I thought you were going to use a straight edge to guide the cutting wheel. But freehand works too.

What speed

what about circles in aluminium too

is it better dremel or jig saw for this?

Thanks! I wasn't sure which bits to use to cut metal computer case because my dremel came with many but without any description at all. I have similar disks and if yours handled sheet of metal that thick I should be fine. Fingers crossed.

Plz tell me which model u have that blue coloured

Good demonstration. I'd be inclined to clamp some wood guides on either side of the cut to make a channel, but then I don't have the steadiest of hands.

good idea

Can you share a link for the tool that you're using?

Its like pulling teeth with this guy!

how do you close this hole after you're done?

Is the lack of sparks due to the tool/cut off wheel or the fact that it is aluminum

Another option to a dremel style tool is to use a pencil micro air grinder such as can be found at Harbor Freight. Electric rotary tools have too much torque and can get away from you Possibly damaging the part. The pencil air grinders have a lower torque and just slow down instead of running away.

Sounds like David Lynch!

Good

damn for $20 that thing sounds like it has a lot more power than the one I got for $20 at the store...

What do you call that attachment for making holes in the corner? It's included in the WEN?

Didn't see the final finish.

aluminum steel thickness n width

welding pen n welding pieces together

The narrator sounds just like David Lynch. I'm completely serious.

Do you know of a high quality, SOLID cutting wheel that is 1 inch in diameter, or just a little bigger? I have a 2004 Toyota Corolla. The dim wit engineer that designed it decided the 2 nuts that hold the donut gasket together, on the exhaust manifold, just had to be WELDED down! There is a lip around each nut, on the end of the exhaust manifold. So I either need: 1: A 1 inch cutting wheel, or just a little bigger, that can do some serious cutting. Using lots of wimpy Dremel cutting wheels does not work. Or 2: A larger cutting wheel, which means I'll have to slice through that lip around the nut. And also some type of rotary tool that has a long and skinny end. A regular cordless drill is just too large to get down behind the engine. It has an exhaust leak. I got 2 headaches, then figured it out. So I have been driving with the windows rolled down. I could take it to Bell's Exhaust, for around $70. But I would REALLY like to cut those 2 nuts off, and replace them with 2 good nuts and bolts, and, of course, replace the donut gasket. Thank you much. Happy Thanksgiving.

power tools

WHat type of dremel (torque etc.) power tool? "Inexpensive" doesn't say much and dollars don't rotate...

rotary tools 🧰

Dremel is much to expensive! Every 5 inches is 1 Dollar of consumed cuting blade.. 🥴

Show how on 22 gauge steel plate...aluminum is easy.

Man I own one and it ear raped me every time I use it to cut steel

Brain surgery is not on you bucket list I assume?