Cutting a boom with a chop saw?

[Concerto]

If using a power saw to cut aluminum, then you should be using a ZTR blade. This has a blade with 3 types of tungsten tip. There will be a left and right tips and then a center clearing tip.

You mention the saw blade is 210mm diameter. That will only give a maximum of about 80mm. Unless it is a very small boom, your saw will not cut through the boom without rotating it. This would be dangerous as when cutting aluminum it should be clamped as it is far tougher than wood and more likely to snatch. So use a hacksaw as already recommended.

 

[fredrussell]

When I worked at a boat builders the boss there, who was VERY strict about correct tool usage, surprised me by suggesting I should use the band saw for cutting some 5mm (if memory serves) aluminium plate. I did, however, get a good bollocking for using same band saw to cut some Kevlar composite sheet.

If it were me I’d go at that boom with a slit disc in an angle grinder.

 

[DownWest]

When I worked at a boat builders the boss there, who was VERY strict about correct tool usage, surprised me by suggesting I should use the band saw for cutting some 5mm (if memory serves) aluminium plate. I did, however, get a good bollocking for using same band saw to cut some Kevlar composite sheet.

If it were me I’d go at that boom with a slit disc in an angle grinder.

Interesting, just recently bought 1mm 125mm dia discs that are multi material. Previously, always concerned that trying to cut alloy with thin discs would clog them and disintergrate. The multi discs cut alloy without hassle.

 

[oldmanofthehills]

When I worked at a boat builders the boss there, who was VERY strict about correct tool usage, surprised me by suggesting I should use the band saw for cutting some 5mm (if memory serves) aluminium plate. I did, however, get a good bollocking for using same band saw to cut some Kevlar composite sheet.

If it were me I’d go at that boom with a slit disc in an angle grinder.

I took 2cm off my boom as it was catching on backstay when reefed which raised it higher.

I used ordinary angle grinder after cutting free the rivets on the end fitting. It took 30 minutes to ponder, 15 minutes tops to cut and 5 to reinsert and re-secure.

Gentlemen we are overthinking the OPs problem - we are well beyond the age of badly flaked flints - we have high tempered blades and possibly even power

 

[penberth3]

Because it is quick easy accurate & neat. Saves a load of work effort.
But if one is incompetent with power tools, then better stick with a toy

Setting up, extension leads, taking down and putting away? The noise and the mess? There's nothing quick and easy about power tools for a one-off job like this.

 

[Blueboatman]

I’ve just thought of another acronym for BOAT:
Buy Often Another Tool

 

[oldmanofthehills]

Setting up, extension leads, taking down and putting away? The noise and the mess? There's nothing quick and easy about power tools for a one-off job like this.

You use cabled non-battery tools in the early 21st century?

 

[Sea Change]

Setting up, extension leads, taking down and putting away? The noise and the mess? There's nothing quick and easy about power tools for a one-off job like this.

Who's to say he doesn't have a chop saw already set up?
When I had to cut a mast it was far and away the easiest, fastest, and most accurate option.

 

[fredrussell]

Setting up, extension leads, taking down and putting away? The noise and the mess? There's nothing quick and easy about power tools for a one-off job like this.

21st century = lithium. I’d have that boom cut while you were still wondering which way round your hacksaw blade went!

 

[Daydream believer]

Setting up, extension leads, taking down and putting away? The noise and the mess? There's nothing quick and easy about power tools for a one-off job like this.

I have a workshop designed for simple mechanical tasks and setting up is a doddle. If anything has to be completed outside the sockets are outside ready. We had a chain cutting session for the mooring holders at my house a week ago & they were all surprised how efficient the operation was.

 

[ProDave]

We won't be actually doing this now until the end of the season. We only just got the replacement boom and the boat is in service now with the old boom, so it is likely to stay like that for this season and making the new boom match the old is now a job for next winter.

It will be done in a domestic garage so no problem plugging in the chop saw if that is what we choose to do. My least favourite of the options suggested is the thin blade on an angle grinder. That has so much more to go wrong. So it will be chop saw or hacksaw, though I will throw one more option into the mix, a multitool. That has a half round saw blade with fine teeth. I might just try that at cutting aluminium. A lot less dangerous than the angle grinder idea.

I will have to check the available depth of cut available with the chop saw, if it is less than the thickness of the boom then that rules that out.

 

[Sea Change]

I would pick an angle grinder over a multi tool for this. Multi tools are of very limited use, generally where you don't have access to get a better tool in. Pretty hopeless for doing a straight line, worse than a jigsaw.
With a small and light grinder it's possible to be pretty accurate and controlled. I use mine frequently for things like trimming the ends of bolts, and the only real limitation is how long I can hold the bolt for before the heat gets too much. Obviously there are safer ways of doing things but just pointing out that they're not really that scary.
The other day I used it to cut a sheet of aluminium out of the side of a boom, on a beach. Effortless, accurate.

My order of preference would be: chop saw (if big enough), grinder, hacksaw. And this isn't due to laziness, it's because I would want the job done right. Every time I try to saw anything by hand it goes off at an angle. Maybe that's just me but with power tools I find I get much better accuracy.

 

[Blueboatman]

I would love a decent gas axe

 

[awol]

Lidl has a mains angle grinder for £19.99 at the moment - just saying.

 

[vyv_cox]

. Every time I try to saw anything by hand it goes off at an angle. Maybe that's just me but with power tools I find I get much better accuracy.

That is why I suggested in a previous post that the correct way to do it is to mark the line first, then follow it with the hacksaw, not attempt to get through with a single cut. It takes years of practice to make a square single cut, whereas anybody can make the blade follow a line.

 

[Sea Change]

That is why I suggested in a previous post that the correct way to do it is to mark the line first, then follow it with the hacksaw, not attempt to get through with a single cut. It takes years of practice to make a square single cut, whereas anybody can make the blade follow a line.

Yes that is absolutely the way I would do it, whether with a hacksaw or a grinder.
The chop saw had the advantage that you can get a square cut without having to mark it all the way around, and the errors that that may introduce.
It will need to be a fairly small boom for it to fit in Dave's chop saw though.

 

[zoidberg]

....It takes years of practice to make a square single cut....

I've put in years of practice. Yessiree...

I've probably managed a single square cut.... and dozens of wonky ones.

Perhaps the best careers advice I've had was 'Don't give up your day job!'

 

[awol]

.

 

[Trailer_sailor]

A couple of years ago I cut a lark boom down to fit a gull using my chop saw. I don't see what the fuss is about if you have the right blade. Quick, accurate, clean. If you want to re use the fitting on the end be super careful. I tried to lever it out and it broke. If I tried it again I would first shorten the boom. Then trim the excess from the bit round the fitting. Then cut longitudinally with a dremel or similar to release the fitting. After drilling the rivets of course.

 

[ProDave]

We already have both end pieces removed so that hurdle is crossed already.