I've read that 3 times and I'm still not sure what you want to do. Could be me though.

First, I assume you're mixing dimensions and the piece is 6" dia and 30 mm thick. I assume (again) that you want to cut the 30 mm dimension in half (i.e. not cutting across a diameter). I also assume you're talking about a horizontal metal-cutting bandsaw (not the vertical, woodworking variety). But what's the bit about holding the aluminum in a drill press and holding the drill press in the bandsaw "chuck"?

Do you mean you want to hold it (across the flat sides) in the drill press vice and then hold that that vice in the bandsaw vice? That won't work on a couple of grounds. Mostly you're clamping the aluminum on both sides of the final cut …. in effect, squeezing the cut together and pinching the blade. Also, normal drill-press vice is too low profile to adequately hold the metal for cutting. That would be made worse by the fact that you'd have to raise it in that vice to avoid sawing the vice itself.

I've done similar operations by holding the cylinder of metal in a lathe chuck, then holding that in the bandsaw chuck …. but those were a much smaller diameter and I doubt it could be successfully done on a piece this big (even if you had a lathe chuck that big).

Needs a bit of thought. Don't ignore wood (knocked together wooden jigs) as a means to hold difficult pieces. Can you allow any fixing holes in the piece?

Apologies in advance if I've misunderstood what you're trying to do.

I agree with the previous two replies. A rough drawing or some pictures of how the drill press would be mounted in the bandsaw would help. Is it a VERY LARGE bandsaw as you plan to mount the drill press in it's vice ?

Les.

I couldn't follow the logic either but recently MEW published an idea of mine for holding awkward short ends for cutting on a horizontal bandsaw. Whether it will help in this case I don't know.

To repeat the idea, bond the piece to a wooden handle or something you can grip in the bandsaw vice using a polyurethane adhesive; after curing overnight the grip is strong enough to need a hammer and chisel to break. I've cur washer thin slices off bar ends by this method.

Brian

Think I would hold in the drill vice, cut down to just above the vice jaws, lift saw, put in a bit of packing in the saw cut, rotate the work, and finish the cut.

Some times it pays to rotate the work on a large cut like that if your saw is not cutting spot on at right angles.

Ian S C

Just a further note: if you are talking about the typical 4 x 6 bandsaw, the height of the stock will be well above the normal height limit for the saw (particularly after you've got it in the drill-vice). I have some doubts about how effective the saw will be in that case ….. at least be prepared to wait a long time.

Of course, if you have the luxury of a really big machine …..

The metal may well be above the hight of the saw, but as its so short it will fit up through the frame, and you don't need to cut the full depth any way, say go through 4". We regularly cut 6" galvanized water pipe with a 6" x 4" band saw, just a case of cut, turn, cut, The saw won't cut right through, there not being enough head room.

Ian S C