Best way to cut this material - Sign board

[Harry Bloomfield]

It has a white, factory painted alloy on each face, with a solid plastic core. The alloy forms a very thin faced outer, a bit thicker than cooking foil....

Some years ago, I acquired some, to reface one of my homemade workshop doors, where the marine ply had become delaminated. Back then, I screwed it to the face of the door, then trimmed the sides to size, using an angle grinder. It did the job, but melted the plastic core in the process, leaving a raw edge. A jigsaw, does similarly.

I have acquired some more of the material, and have the second workshop door in need of refacing. So what's the best way to cut it cleanly to size please?

 

[ajohn]

I'd suggest a Stanley knife and a straight edge. Clamp up so nothing moves while cutting it.

 

[scbk]

I've cut it plenty of times using a slitting disc on the grinder then a rub with a file afterwards

 

[robinbanks]

I'd vote a TCT bladed circ saw

 

[Nwgs2]

Circular saw or an old hand saw ?

 

[Harry Bloomfield]

I've cut it plenty of times using a slitting disc on the grinder then a rub with a file afterwards

I tried that last time - problem was, it generated heat, melted the plastic, and jammed the blade.

 

[Brigadier]

Ask the original supplier how they cut it to size (unless they manufacture it to size, of course).


Failing that, phone around some local friendly engineering places, see if any have any clever cutting solutions (water or gas-cooled, for example)?

 

[Brigadier]

Or, cut it slightly smaller than you need, and finish the edges with aluminium angle?

 

[freddiemercurystwin]

Sounds like it might be Dibond, or one of it's competitors product: https://www.google.co.uk/search?q=h...IBgGQBgiSBwQxNC40oAehigE&sclient=gws-wiz-serp

 

[Harry Bloomfield]

Sounds like it might be Dibond, or one of it's competitors product: https://www.google.co.uk/search?q=how+to+cut+dibond&sca_esv=6350d5eca2fae0eb&sxsrf=ADLYWILoCClEr75xNsi1tJJdTUH5naBzmQ:1728466378147&ei=yk0GZ4LbCMfRhbIPldyvmQY&ved=0ahUKEwiC6OaD_4CJAxXHaEEAHRXuK2MQ4dUDCBA&uact=5&oq=how+to+cut+dibond&gs_lp=Egxnd3Mtd2l6LXNlcnAaAhgCIhFob3cgdG8gY3V0IGRpYm9uZDILEAAYgAQYkQIYigUyCxAAGIAEGJECGIoFMgYQABgWGB4yCxAAGIAEGIYDGIoFMgsQABiABBiGAxiKBTIIEAAYgAQYogRIkyFQ2gZYrB9wAXgBkAEAmAF-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&sclient=gws-wiz-serp

That sounds like the material.

 

[scbk]

I tried that last time - problem was, it generated heat, melted the plastic, and jammed the blade.

What discs are you using? As I say I've cut plenty with the slitting discs (probably on the battery grinder), it goes straight through it like a hot knife through butter

 

[Harry Bloomfield]

What discs are you using? As I say I've cut plenty with the slitting discs (probably on the battery grinder), it goes straight through it like a hot knife through butter

Some years ago, but I think it was a 0.5mm metal disc. Hot knife through butter, was the problem - it melted the plastic core, jamming the blade.

 

[robinbanks]

hot knife through butter

Melted butter? Like melted plastic perhaps?

Edit: didn't see you'd cracked the same quip til I'd posted

 

[robinbanks]

0.5mm metal disc

They do tend to melt plastic as well as grind it away.. I'd say you should be looking more for a cut than a grind..

If you need any oddness to the shape like curved cutouts for door handles etc I'd say use a water jet cutter if there is a local co willing to do it at a reasonable price. I'd expect about 30 quid per cut from my local place based on past experience - as a material it would probably cut at quite a high speed which brings the price down

 

[blup]

Jigsaw plus suitable down cutting blade, clamp a length of timber underneath to prevent breakthrough