I would imagine that a course blade and WD40 would help [fine blades clog up with Ali ]

50×50 is not too big and the exercise will help to build up a thirst to justify a trip to the pub later on.

Plan "B" would be to buy a Chinese junk bandsaw, like mine, still going strong after 20 years, and let it do the cutting while you do something else [like drinking the afore mentioned beer ] Just looking at it working would give a thirst. How do I know ? Ask me !

Life is too short to waste your time in that manner, cop yourself on. I gave up that game long ago and now use the hacksaw only when I have to. That,s what bandsaws were made for.

Hi Chris,

Try some chalk on the blade and in the cut, it helps stop the aluminium clogging the teeth. At the end of the day, big teeth, wide kerf and a bit of sweat. Oh sorry, and beer!

Yes, 18tpi blades and use paraffin to lubricate the cut and to help wash out the chips (it doesn't need much).

Peter G. Shaw

Now, as for technique with your new blade:

With the bar in your vice, start sawing 'uphill' (from bottom front to top mid) then saw 'downhill' (from top mid to rear bottom). This will give you an inverted V shaped slot. Cut off the apex then resume as before. The logic behind this is that your cuts are shorter than just cutting straight across the bar.

Thanks to Tubal Caine (Tom Walshaw) for this method.

Now I've got a power hacksaw, my muscles have become all flabby without the use of Armstrong's Patent.

Dave
The Emerald Isle

I feel your pain, I went through the same with a 3 x  1 1/2 section and purchased a bandsaw for the next time!
Seriously though the coarsest blade you can get and WD40 should help.

Edited By Stuart Bridger on 04/09/2020 16:24:23

Don't ask how I know, blush, but a common beginner mistake is sawing too fast and with too much pressure.

Let the tool do the work! Gentle down pressure only with each cutting stroke taking about a second. Also try to use the full length of the blade otherwise all the wear occurs in the middle, and the blade goes blunt quickly on the section doing all the work. Have a good look at the teeth in the centre of the blade through a magnifying glass – they may be blunt or clogged. Dump blunt blades.

Blades wore quickly and sawing was exceptionally hard work when I started. They last longer and the job is easier now my technique has improved. I put it down to learning to work the teeth in the sweet spot between excessive wear due to forced cutting, and blunting caused by rubbing. Teeth should cut with as much of their edge as possible but no more. Forcing a blade deeper than the length of its teeth causes severe wear and multiplies the effort needed to remove metal.

In other words, try slowing down and don't force the blade into the metal.

I love my cheapo 6×4 band-saw! Sawing by hand is too tiring and tedious.

Dave

How can you tell if a cut off disk is rated for aluminium? Is there a special symbol? Searching for 'aluminium cut off disk' doesn't help because they all contain aluminium oxide.

Like me, S-O-D got a pain in his butt with the hacksaw !!

Long live the cheapy junk bandsaw !!!!!

i use 1mm cut off blades in my angle grinder, they work fine.

The cheapest I can find>

Roy, yes for aluminium.The blades are designated for cutting stainless steel and they do not clog up on aluminium.