How to Cut and Assemble Square Aluminum Extrusions for Home Improvement

Square aluminum extrusions offer numerous advantages for home improvement projects. They are lightweight, durable, corrosion-resistant, and versatile. Whether you’re building a new deck, constructing a pergola, or installing a privacy screen, understanding how to cut and assemble square aluminum extrusions is crucial for a successful outcome.

Cutting Square Aluminum Extrusions

Use a Miter Saw: A miter saw provides clean, precise cuts at various angles. Ensure the saw is equipped with a carbide-tipped blade specifically designed for cutting aluminum.

Measure and Mark: Before cutting, accurately measure and mark the extrusion where you want the cut to be. Use a carpenter’s pencil or a marking knife.

Secure the Extrusion: Clamp the extrusion securely to a stable work surface. This prevents movement and ensures a clean cut.

Set the Miter Saw Angle: Measure the desired angle and adjust the saw blade to the corresponding angle. Double-check the angle before making the cut.

Assembling Square Aluminum Extrusions

Dry Fitting: Before applying any adhesive or fasteners, perform a dry fitting to ensure the extrusions fit together properly.

Use Corner Brackets: L-shaped corner brackets provide a strong and durable connection between perpendicular extrusions. Secure the brackets with self-tapping screws or bolts.

Apply Adhesive: Apply a high-quality construction adhesive specifically formulated for bonding aluminum. Use a thin, even layer along the contact surfaces of the extrusions.

Clamp and Cure: Clamp the assembled extrusions together and allow the adhesive to cure according to the manufacturer’s instructions. The curing time may vary depending on the type of adhesive used.

Use Fasteners: In addition to adhesive, you may also use self-tapping screws or bolts to reinforce the assembly. Pre-drill pilot holes before inserting the fasteners to prevent stripping the aluminum threads.

Helpful Tips

Wear safety gear such as gloves, eye protection, and a dust mask.

Use a sharp blade and replace it regularly for optimal cutting performance.

Measure twice, cut once to avoid mistakes.

Practice cutting and assembling on scrap extrusions before working on the actual project.

Allow ample time for the adhesive to cure before placing any weight or load on the assembled structure.