Brian.

This is the saw I use to cut this 6 mm, ¼ inch aluminum. (How do you call this saw, a “fretsaw”?)
Saw blades I use, “piercing saw blades for metal”, brand “Eberle” number 0.

After cutting of course the normally used files and drilling- and thread tools.

Very important is, using cooling liquid, “spiritus” (Dutch), spirit is maybe the right translation. Keep the cutting area of the material continuous wet by dripping a little bit of this liquid (drops!) on it. (sawing, drilling, making thread)
Without this liquid it’s not possible to saw the aluminum or make a good thread in it!!!!

You also can use less thick aluminum but you cannot use threaded holes I think.
I also do use this saw to saw all the wood of my planes, it allready has hundreds of feet on the counter.


Cees