How to Cut Fins in Aluminum

Cutting fins into aluminum is a great way to give your car, aluminum soapbox or other structure some wind resistance and style. Whether you are cutting fins into aluminum for work or as a hobby, once you learn how you will be able to do it again and again. Cutting fins in aluminum may seem like a daunting task at first, but with the right tools and a few basic materials it is a job that can be executed smoothly and successfully.

Things You'll Need

• Permanent Marker
• Safety goggles
• Straight-edge or metal ruler
• Craft or utility knife
• Circular saw equipped with an aluminum cutting blade

Instructions

1. Use your permanent marker to indicate where on the aluminum you would like your fins to go. Draw a thin but clear line from top to bottom.

2. Put on your safety goggles to protect your eyes from any aluminum shards that may be released or airborne during the cutting process.

3. Use a utility knife to cut along the pre-marked area. Hold the straight edge against the blade as you work, going over the pre-marked line again and again until a slit is cut. Push the left side of the aluminum panel away from you, separating the aluminum at the site of the cut and creating a fin. This will work mainly for very thin aluminum sheeting. For more heavy-duty aluminum, move on to Step 4.

4. Get out your circular saw and adjust the depth table to the thickness of the aluminum and begin to cut into the aluminum at the pre-marked area. Cut from top to bottom, carefully, making sure that no other surfaces are cut.

5. Repeat Steps 1-4 for any remaining fins that you would like to cut in.

References

• Submarine Boat: Cutting Aluminum