P3D Re: working with aluminum

[JNorman805@xxxxxxx]

PD asks, with reference to aluminum stock:

<< Is this the L-shaped stuff?  What sorts of tools can you use for cutting, 
 grinding and drilling this stuff?  I want to make a bracket, but I don't 
 know how to cut it to length, round the sharp corners, and drill holes for 
 the screws.  I've done these with wood, but I don't know about aluminum. >>

This is pretty soft stuff.  Use an ordinary hacksaw to cut it.  Use any metal 
file to round the edges and remove the burrs.  Ordinary drill bits that you 
get in any hardware store will drill through this stuff, using a hand-held 
electric drill.  Tip: use a center punch to whack a starter point where you 
are going to drill, in order to prevent the drill from "walking" away from 
the intended plce where you want to put a hole.  Also, you'll get faster 
results and the bit will retain its edge longer if you use a few drops of 
lubricating oil (like 3-in-1) on the drill bit and the work-piece.  
CAUTIONARY NOTES:  Aluminum has a tendency to bind at the end of a drill cut, 
especially if you haven't been diligent about lubrication, and spin around 
violently with the drill bit.  That can cause a nasty cut, or even a broken 
finger.  Clamp the workpiece securely to a large scrap wood board.  Also, 
drilling aluminum can throw off small chips or spirals of cut metal, so use 
eye protection.

Jim Norman