How to Cut Aluminum With a Dewalt Miter Saw

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A Dewalt miter saw equipped with the correct blade can cut lightweight aluminum easily. All Dewalt saws come equipped with carbide-tipped blades, which are much stronger than regular steel blades. Tungsten carbide, applied to each saw tooth when the blade is manufactured, is one of the hardest man-made materials. Regular steel blades will melt the aluminum, and abrasive blades will create aluminum dust that can ruin the saw motor.

Things You'll Need

  • Dewalt miter saw
  • carbide-tipped saw blade
  • wax lubricant, Crisco or WD-40
  • Check the blade in your saw to ensure it's a Dewalt carbide-tipped or carbide-toothed blade. If the blade is regular steel or an abrasive wheel, remove it and replace with a carbide-tipped blade.

  • With the saw unplugged, apply lubricant wax to the saw blade. The wax helps reduce friction during the cutting procedure, ensuring a cleaner, burr-free cut. In addition, the wax makes sure pieces of aluminum do not weld to the saw blade during the cut. You also can use Crisco or WD-40.

  • Place your aluminum onto the saw base, and make sure it's flush against fence. Mark the spot where you need to cut, and line up that spot with the blade.

  • Depress the power switch. In a smooth motion, lower the blade into the aluminum. Thinner pieces of aluminum will be cut quickly, and thicker pieces will take longer for the blade to pass through.

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