Best Way To Cut Aluminum Sheets

Tired of getting fingers cut on sheet metal while using tin snips.

Best way to cut aluminum sheets.

Then grip the saw with both hands and push the blade through the metal to cut it. For thin sheets of metal you can use tin snips to cut through it. Create a long fracture line then progressively bend the sheet from one end to to the other. If possible choose a saw blade that creates narrow kerfs the notch or slot made by the saw.

Mount a diamond blade in your angle grinder and use it like a saw to cut the mesh. Use a wood cutting saw with carbide tipped blades to cut most aluminum. We recommend using a diamond blade that s labeled as a ferrous metal cutting blade but many tradespeople use a regular masonry diamond blade with good results. Cutting aluminum sheet metal with a hammer and chisel is relatively straight forward line up the edge of the chisel along the line you wish to cut and strike the chisel with a hammer.

With care and patience full size sheets of aluminium can be cut using this method. Start by taping both sides of the sheet metal directly over the line you want to cut and clamp the metal to a work station so it doesn t move. Using a softer piece of material such as wood as a backer will allow the chisel to push through the metal and prevent wear on the chisel s tip. After a few wiggles the sheet will fracture along the cut line leaving a clean break as shown in the above photos.

Auto hobbyists and handypersons sometimes have the need to cut aluminum sheeting and don t always have the luxury of going to a metalworking shop to take care of it. How to cut thin aluminum. Flip the sheet over and repeat. Metal lath and hardware cloth can be cut with a tin snips but there s an easier way.

To cut straight lines use an electric saw.