One of the questions I get asked all the time is, "What cordless tools do you use the most?"
After hundreds of hours spent building this aluminium boat, these are the cordless power tools I reach for more than anything else. There are plenty of other tools I use, but if I had to choose the ones that have had the biggest impact on the build, this would be the list.
1. Two Cordless Grinders
If there's one recommendation I'd give anyone working with aluminium, it's to own two cordless grinders.
The amount of time it saves is surprising. I keep one grinder permanently fitted with a sanding disc or flap disc, while the other is set up with a carbide-toothed wheel—either a milling disc or a cutting disc. Instead of constantly swapping discs, I simply grab the grinder I need and keep working.
One thing I always do is make sure the grinder running the carbide-toothed disc has a dead man switch fitted, and I always use the side handle. These discs remove material quickly, so maintaining full control of the grinder is essential.
2. Hand Trimmer (1/4" Router)
A hand trimmer is one of my favourite finishing tools for aluminium fabrication.
They're excellent for cleaning up aluminium plate, especially anything 4mm thick or more. One thing many people don't realise is that you can use router bits designed for wood when machining aluminium, provided you're using them correctly.
My personal favourite is a 2mm radius bit. It puts a smooth radius on plate edges, making them look more professional while also removing the sharp edges that can easily cut your hands during assembly.
3. Palm Orbital Sander
For most fabrication work, a palm orbital sander is more than enough.
If you're only sanding occasionally, there's no need to spend a fortune on larger sanding systems. A quality cordless orbital sander handles most finishing work with ease and is one of those tools you'll find yourself reaching for far more often than you expect.
4. Cordless Drill
Cordless drills have come a long way over the last few years.
If you're buying one today, I'd recommend buying the biggest and most powerful model you can justify. Drilling large holes—like using a 100mm hole saw through 5mm aluminium plate—is a serious workload for any handheld drill.
5. Impact Driver
An impact driver isn't essential, but it's definitely one of the most useful cordless tools in my workshop.
I use mine regularly with our Saber Drill Set, and the drill bits cut through aluminium like butter when used with an impact driver.
It's also ideal for our Drill and Tap Set, making quick work of tapping holes without constantly changing tools.
6. 2" Sander/Polisher
This is another tool that isn't essential, but it's incredibly handy to have.
A 2-inch sander/polisher is perfect for sanding smaller components, cleaning welds in tight areas and reaching places that larger sanders simply can't access. Once you own one, you'll find plenty of uses for it.
7. Circular Saw
A cordless circular saw is one of the quickest ways to make long, straight cuts in aluminium plate.
With the correct blade fitted, it produces accurate, clean cuts while saving a huge amount of time compared to other methods.
For aluminium, I recommend using our 160mm x 60T Alucut Blade, which has become one of my go-to choices for my circular saw.
Final Thoughts
These are the cordless power tools that have earned a permanent place in my workshop. Every one of them has been used repeatedly throughout the aluminium boat build, not because they're the newest tools available, but because they've proven themselves over countless hours of real fabrication work.
If you're planning your own aluminium project, starting with these tools will put you in a great position. Throughout the boat build, you'll see every one of them in action, and over the coming months I'll be sharing more of the techniques and workshop tips I've learnt along the way.
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