How to Cut and Join Rectangular Aluminum Extrusions for Optimal Results

Aluminum extrusions are a versatile and cost-effective material for a wide range of applications, including framing, signage, and enclosures. Cutting and joining rectangular aluminum extrusions is a relatively simple process, but it is important to follow the correct procedures to ensure optimal results.

Preparing for Cutting and Joining

Before cutting and joining rectangular aluminum extrusions, it is important to prepare the materials and equipment. This includes:

Measuring and marking the extrusions to the desired length

Selecting the appropriate cutting tool, such as a hacksaw or miter saw

Choosing the appropriate joining method, such as welding, riveting, or mechanical fasteners

Gathering the necessary safety gear, such as safety glasses and gloves

Cutting Rectangular Aluminum Extrusions

When cutting rectangular aluminum extrusions, it is important to use a sharp blade and to make clean, precise cuts. This will help to ensure that the extrusions fit together properly and that the joints are strong.

– Hacksaw: A hacksaw is a simple and inexpensive tool for cutting rectangular aluminum extrusions. However, it is important to use a hacksaw blade that is designed for cutting aluminum and to make sure that the blade is sharp.

– Miter Saw: A miter saw is a power tool that can make precise cuts in rectangular aluminum extrusions. Miter saws are more expensive than hacksaws, but they can save time and effort, especially when cutting multiple extrusions.

Joining Rectangular Aluminum Extrusions

There are a number of different methods for joining rectangular aluminum extrusions, including welding, riveting, and mechanical fasteners. The best method for joining aluminum extrusions depends on the specific application.

– Welding: Welding is a strong and permanent method for joining aluminum extrusions. However, welding aluminum requires specialized equipment and skills.

– Riveting: Riveting is a simple and inexpensive method for joining aluminum extrusions. However, rivets can be visible and may not be suitable for all applications.

– Mechanical Fasteners: Mechanical fasteners, such as bolts and screws, are a versatile method for joining aluminum extrusions. Mechanical fasteners are easy to use and can be removed and reused if necessary.

Finishing Touches

Once the extrusions have been cut and joined, it is important to finish the edges to remove any burrs or sharp edges. This can be done with a file or sanding block.

Tips for Optimal Results

In addition to following the steps outlined above, there are a few additional tips that can help to ensure optimal results when cutting and joining rectangular aluminum extrusions:

Use a cutting lubricant to help prevent the blade from binding and to extend its life

Clamp the extrusions securely before cutting to prevent them from moving

Make sure that the joining surfaces are clean and free of debris

Use the correct size and type of fasteners for the application

Test the joints to ensure that they are strong and secure