Sidebar: Machining My Aluminum Squares

Cutting Width and Length Dimensions

(1) For cutting, I use my Makita 9.6V handheld wet saw. I could have used a hacksaw, but the Makita was faster, cleaner, and more precise.

(2) I clamp the aluminum bar from Home Depot to my Black and Decker Workmate.

How I Planed to Thin the Aluminum Squares

(1) I use a bastard file to grind down the thickness of the (2) aluminum square.

(3) I have chiseled a slightly oversized recessed square to secure the aluminum square while I file it to the correct thickness.

Filing Aluminum Square to Thickness

I just chiseled a very shallow square into an old worktable to hold the aluminum square. After trial fittings, I settled on a thickness of 1.47mm.

I was amazed at how fast I was able to shave the aluminum square down. This aluminum bar is incredibly soft and easy to work with.

Next, I smoothed the aluminum square surfaces using sandpaper. Remember, the smoother the surface, the better the heat conduction.