Cutting aluninum intakes

[FERoadster]

Joe: when you say bandsaw what type are you using? Is it a wood band saw with high FPM blade speed or a metal cutting band saw?
EDIT: also Joe what are the blade dimensions , thickness and width (depth)?
Richard

[AlanCasida]

I have the same intake on my adapter. Since I tend to over think things, I was concerned the intake might be under some stress and completely removing the underneath part might release the stress causing the manifold to become warped. So I left some the under side in place. To add to my concern, when I made my V cut on the front side of the intake it popped a little when I got right to the end of my cut. I used a combination of a hole saw and a cutoff wheel on my angle grinder to get my desired cut.

[gregaba]

Alan
I will let you know Monday night if my new saw blade comes in.
I am going to cut out the whole bottom.
Greg

[Joe-JDC]

Joe: when you say bandsaw what type are you using? Is it a wood band saw with high FPM blade speed or a metal cutting band saw?
EDIT: also Joe what are the blade dimensions , thickness and width (depth)?
Richard

1/2" x 14 x 84" table bandsaw with 10" space, more with up to 45* angle cut.  Metal cutting blade for hardened aluminum plate.  Joe-JDC

[gregaba]

Went to cut the intake yesterday on my neighbors table saw.
He has a high dollar one that has a electronic finger saver on it.
He went to cut it and the finger guard tripped stopping the blade. Man that thing works.
Anyway we have to buy a new unit before the saw will work again. Will get the part tomorrow [$70].
Here is a picture of the part.
He was wearing leather gloves and the sensor still tripped.
He said tomorrow he will lock it out so it doesn't happen again.
So if you have a finger saver on your saw you will have to disable it before you use it or wear rubber gloves.
Greg

[cjshaker]

He has a high dollar one that has a electronic finger saver on it.
He went to cut it and the finger guard tripped stopping the blade. Man that thing works.

I don't know how his works, but the ones I've seen are brutal when they go off! They really do work, but man do they destroy some stuff when they engage.

[gregaba]

I was standing right next to the table watching and it was fast. He said it usually ruined the blade when it stopped it.
We took the blade off and their was no damage at all.
New $130.00 blade so I am happy I don't have to order another blade.
We will have a new one tomorrow and see if we can get it cut.
Greg

[gregaba]

Update
I thought I would post a picture with the cuts we just did on the intake.
This cut was super easy. We started with a 1/8 inch cut and just cut a little more each time.
Was surprised at how quiet the cut was and didn't really have as many shaving's as I expected.
Still have to make the front cut for it to sit right but for now here are a couple of pictures so you can see how it is going to look with the Lexan valley cover.
Greg

[gregaba]

Ok
Here's the other picture.
Greg