Bandsaw Blades for cutting Aluminum?

The blade in my bandsaw broke yesterday.  Probably a blessing in disguise...

I've never been happy with it.  The blade was the one that came with it, and I was never able to cut a straight line with the thing.   Cutting aluminum, such as extrusions, was extremely loud, even with hearing protection.

Now that I need a new blade, what's a good one to get for cutting aluminum of the sizes that we use...? 

How many teeth per inch?  Bimetal or not?  Are wider blades better than narrow ones?

What works for you guys...?

Thanks,

Patrick
XL/Corvair/N63PZ

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Permalink Reply by David Gallagher on April 9, 2010 at 2:04pm
Here is one of the EAA videos on cutting aluminum with a band saw. His method works for me.

http://aeropunk.com/builders-log/knowledge-base/cutting-aluminum-on...

I have also heard about waxing the blade but I have never done that..
Permalink Reply by Peter Sonders on April 9, 2010 at 5:19pm
Patrick,

I am using a "Raker" bandsaw blade with at least 14tpi and the wider blades work better for straight cuts. Check www.grizzly.com .They have a lot of different bandsaw blades in stock.

Peter Sonders
Permalink Reply by Phill Barnes on April 9, 2010 at 7:33pm
Hi Patrick
I just use a standard wood cutting 1/2" wide 6 tpi blade. It cuts effortlessly, cleanly and straight every time. These blades are great because if you do happen to break them, they are only $15 AUD to replace. After lot of aluminium cutting I can put a block of pine through the saw and it still cuts like new. Usually if a band saw blade breaks it is because it tensioned to tightly but of coarse there are other reasons.
One hint though, when cutting angles, place them over the edge of a block of wood and clamp them with your hands and you will achieve great control of your cut.

Regards
Phill
Permalink Reply by Brad Rawls on April 9, 2010 at 7:54pm
Find a Lennox saw blade store in your area and talk to them. They can make any length and TPI blade that you need while you wait, and it will be half the price of anywhere else you can find. I told them what I was doing and they recommended a 14 TPI and made it for $10.
Permalink Reply by Patrick Hoyt on April 18, 2010 at 9:56pm
Just wanted to follow up on what I ended up doing.

I bought a new blade that's wider than the original one, and has more teeth per inch. About 1/4" wide, and 14 teeth per inch.

Also, when I opened up the bandsaw so I could put the new blade in, I found some guide rollers that were all out of whack. I adjusted everything so the blade would run through it straight, and tightened everything down.

It's a totally different tool now. Cuts fast and straight now. Not as loud as before, either.

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