Tips for Cutting and Installing Rectangular Aluminum Extrusions

Rectangular aluminum extrusions are highly versatile building materials with a wide range of applications. They can be used for framing, roofing, siding, and countless other purposes. However, cutting and installing rectangular aluminum extrusions requires precision and attention to detail. Here are some essential tips to ensure a successful project:

Cutting Extrusions

1. Select the Right Cutting Tool: Use a fine-toothed hacksaw, miter saw, or circular saw with a metal-cutting blade. Never use a saw blade intended for wood cutting.

2. Secure the Extrusion: Clamp the extrusion firmly in place before cutting. This will prevent it from moving while you’re sawing.

3. Measure and Mark Accurately: Measure and mark the desired cut location carefully. Use a square or framing level to ensure precision.

4. Cut Slowly and Carefully: Apply light pressure while sawing to avoid tearing or gouging the extrusion. Use smooth, even strokes and keep the blade perpendicular to the material.

5. Deburr the Edges: Remove any sharp edges or burrs from the cut surface using a file or sanding block. This will prevent injuries and improve the extrusion’s appearance.

Installing Extrusions

1. Plan the Layout: Determine the placement of the extrusions based on the intended application. Use a level and measuring tape to ensure accuracy.

2. Prepare the Surface: The surface where the extrusions will be installed should be level, clean, and dry. If necessary, use shims or spacers to level the surface.

3. Attach the Extrusions: Use the appropriate fasteners for the application and material type. For example, use bolts and nuts for permanent installations or screws for temporary or removable installations.

4. Seal the Joints: Seal all joints and connections with a compatible sealant to prevent moisture infiltration. Use a caulking gun or brush to apply the sealant evenly.

5. Inspect Regularly: Regularly check the installation for any signs of damage, loose fasteners, or sealant failure. Make any necessary repairs or replacements promptly.

By following these tips, you can ensure precise cutting and secure installation of rectangular aluminum extrusions, resulting in a professional-looking and durable project.