How to cleanly cut aluminium

Outside of a plasma cutter + argon, what method of cutting aluminium will leave me with the cleanest cut? I experimented with a harbor freight cutoff wheel and came away unimpressed. I've heard a jigsaw suggested, any other clever ideas?

I'm trying to replicate this:

Nibbler http://www.harborfreight.com/catalogsearch/result?q=nibbler

I've had pretty good luck with a cutoff wheel on miata aluminum hoods. It can help to put a layer of good masking tape down on the area that you're going to cut before going to town. Also, it takes a pretty steady hand. Also also, the cutoff wheels cut much better when cutting in one direction vs the other (like climb vs conventional milling) - I don't remember which one though.

I don't know about those nibblers in particular, but some of the ones I've used before can bend the sheet metal around the cut. Probably was an old crappy one with dull blades, but something to watch for.

For reference, I cut the vents and hole for the supercharger in this hood with a cut off wheel.

I've had decent luck with cutoff wheels, you can get thinner ones to make a more precise cut.

I have used a sabre saw with a fine tooth blade. At least 24T to 32T per inch.

The thinnest high quality wafer disc you can get.

HF grinder, DeWalt wheels.

-J0N

Tape down a flexible straight edge to help cut straight. I've used semi thin strips of aluminum for this before. The cut off wheel cuts are more impressive once you go back and clean up the edges. Go thin. Go slow and allow the heat to dissipate.

And follow up with a file.

I have used a cutoff wheel on a dremil... that was a -very- long day

http://www.harborfreight.com/high-speed-metal-saw-91753.html

EDIT: Another way I've done thin stuff that is hard to keep from flibbering with a recip blade is to press/clamp/screw/etc it onto a piece of plywood or paneling and use the a saw to cut thru both.

Again, use painter's tape if using a recip type saw... it will keep you from scratching the face where you drag the saw along.

tr8todd wrote: Tape down a flexible straight edge to help cut straight. I've used semi thin strips of aluminum for this before. The cut off wheel cuts are more impressive once you go back and clean up the edges. Go thin. Go slow and allow the heat to dissipate.

Great advice up in hur

I cut aluminum diamond plate half-doors for my Samurai with a circular saw with a wood blade turned backward.

Recommended to me by the guy I bought the 4x8 sheet from. I was skeptical at first but lo and behold, it worked!