I have some intercoolers and fuel tanks to make using 1/8 aluminum. I was going to use a jig saw but i been looking for a quicker easier and more consistant way. I have considered using a cnc plasma table as i have acess to one. Making nice clean cuts is not a problem. I have heard that plasma cutting can cause microscopic cracks at the edges. Which in my mind would not be good for an intercooler that will see 44-100psi+ in the application it will be used. Anyone have experience with this? I have also considerd using cnc router setup which i think would work well for making all sorts of parts.

 

i have never seen cracked/failed aluminum from plasma had i have made fuel cells, and various other bits working in ship fitting. i think you will be ok

 

use the CNC. you will be fine.

if not, just use a standard circular saw. works great on aluminum.

 

Water jet is optimal. Cnc will get the job done as well as a hydraulic sheer. Laser works ok but does not like the reflection from the aluminum.