Best Way To Cut Aluminum Sheets

Mount a diamond blade in your angle grinder and use it like a saw to cut the mesh.

Best way to cut aluminum sheets.

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. 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. Metal lath and hardware cloth can be cut with a tin snips but there s an easier way. Then grip the saw with both hands and push the blade through the metal to cut it.

Tired of getting fingers cut on sheet metal while using tin snips. Select a fine toothed blade and don t cut aluminum with a wall thickness of more than 1 4 inch 0 64 cm. 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. Create a long fracture line then progressively bend the sheet from one end to to the other.

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. If possible choose a saw blade that creates narrow kerfs the notch or slot made by the saw. Check out this video. With care and patience full size sheets of aluminium can be cut using this method.

For thin sheets of metal you can use tin snips to cut through it. Use a wood cutting saw with carbide tipped blades to cut most aluminum. Flip the sheet over and repeat. 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.

After a few wiggles the sheet will fracture along the cut line leaving a clean break as shown in the above photos.