If you havent made frames before dont offer to do so unless you have a table saw. It’s not very likely you will get desirable results with manual methods.
Also another way to mitigate the risk of messing up the frames is just take the sizes you need into your store thats gonna do the cutting. Make them measure it. That way if you get bad sizing you have something to fall back on if pieces to fit correctly.
Epic fail for frame cutting today… but a great lesson learned for sure.
are you talking about building frames for windows or screens?
Are you doing mitered corners or using corner pieces?
When I am rebuilding mitered corners for screens, I mark the 45 angle on the frame metal with a sharpie. Then I take masking tape, wrap the metal along the sharpie line and then keep wrapping the tape to build up a “stop” along the line. Get out the Dremel with the cut off wheel and cut along the line using the masking tape as a stop guide to keep your corners sharp.
Yeah for the mitered corners. I tried using regular hand saw. I think thats a great idea for onceys and twoseys but it was so much easier to just have city mill do it. Either way the customer is saving money and Im still making more than i would have before had I not replaced the frames… new frames are also soooo much easier to screen.
Mitered 45 degree corners are better with metal carner inserts. If you have to use plastice try and find uv rated nylon. Here in az plastic corners get heat and uv blasted and last only a few years before they crack .
I admit I used to use a wood blade to cut screen frame. Since aluminum is so soft it cut right through it, just not very smoothly. After the cut I used my grinding wheel to smooth the edges. Since I now have the appropriate blade there is no need for the extra step. No melting or burred-edges. Just perfectly clean cuts.
you can use carbide tipped blades to cut aluminum. that’s what everyone uses. they make blades specifically for cutting aluminum too and all they are is carbide tipped blades lol.
but they have a lot of teeth and are very thin so they cut very nicely with clean edges.
this blade here is one of the best ones I’ve ever used for cutting aluminum.
I used to build sunrooms etc that were 100% aluminum structures. all we use to cut everything was carbide tipped blades.
the hard part of doing screens is to actually wire the screen frame. when you can do it good, then you’re in business. it takes a lot of practice. I’ve become a master at doing them. so good you couldn’t tell mine from a factory unit.
do yourself a favor and get a quality screen rolling tool. like this one, Everhard Spline Rollers and Other Tools for Assembling Screens and Sash