Metal Magic: Cutting and Shaping Angle Aluminum


In another segment of KITPLANES’ Metal Magic series, editor at large Paul Dye shows you how to accurately cut and artfully shape even large and thick aluminum angles.

This series is sponsored by Aircraft Spruce & Specialty.

View the complete list of published Metal Magic videos.

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  1. Very nice information. If I may add my $0.01 if you don’t have a bandsaw or on some of the complicated cuts you can use 3-4″ angle grinder with a cutoff wheel. In fact I find myself grabbing it more often than not. I have a small and large Vice just for that purpose. The Jaws are fitted with nylon instead of knurled Steel. This prevents marring of the aluminum. Then to finish the part I can use either the belt drum or disc Sanders. And I almost always knock the corners off. Not only does it give a cleaner look but inevitably you will bump part of your body against that sharp corner, and it won’t be good. LOL

  2. It looks like you were cleaning up your aluminum with a grindstone and not a sanding wheel although you did say Scotchbrite just before you started. Using a Grindstone embeds aluminum particles in the wheel and can cause the stone to explode.

    A Scotchbrite wheel which is the right tool. In the video though this looks like a regular grinding wheel and some people may not realize that’s not what you were using. It might be worth a specific comment that these were not stone wheels in your grinder but Scotchbrite that looks like grinding wheels. An example of what I use is


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