Ways To Cut Aluminum Sheet

Create a long fracture line then progressively bend the sheet from one end to to the other.

Ways to cut aluminum sheet. 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. And you can use the same technique anytime you need a straight cut on aluminum or other light gauge sheet metal even steel. To cut straight lines use an electric saw. Clamp or hold a straightedge or square along the cutting marks and score a line with the tip of a sharp utility knife blade.

Next secure your aluminum pieces with clamps and slowly feed the aluminum through the blade using steady even pressure. A handheld cutting tool fitted with a metal cut off wheel will easily cut through sheet. 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.

Apply a lubricant like standard oil or saw wax to your blade then slow your cutting speed by reducing the diameter of the cutting blade. 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. 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. Jigsaws and metal cutting band saws are more work but can make most cuts in light to medium sheet metal.

Then bend the sheet back and forth a few times to snap it. After a few wiggles the sheet will fracture along the cut line leaving a clean break as shown in the above photos. To cut aluminum use a wood cutting saw with carbide tipped blades.