Cut Through Thin 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.

Cut through thin aluminum sheet.

Check out this video. The illustrations are for a small bracket but i have cut 3 foot. Cutting thin aluminum should require no more than a few basic tools and is therefore a task that can be easily tackled either on the spot or from any reasonably well equipped garage. If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly.

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. Then grip the saw with both hands and push the blade through the metal to cut it. Use a wood cutting saw with carbide tipped blades to cut most aluminum. Select a fine toothed blade and don t cut aluminum with a wall thickness of more than 1 4 inch 0 64 cm.

If possible choose a saw blade that creates narrow kerfs the notch or slot made by the saw. 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. To cut straight lines use an electric saw. For thin sheets of metal you can use tin snips to cut through it.