Cut Through Thin Aluminum Sheet

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.

Cut through thin aluminum sheet.

How to cut thin sheet metal and keep it flat. Tired of getting fingers cut on sheet metal while using tin snips. If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly. 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.

These photo steps show that it can be done using a utility knife. Use a wood cutting saw with carbide tipped blades to cut most aluminum. Then grip the saw with both hands and push the blade through the metal to cut it. Check out this video.

To cut straight lines use an electric saw. 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. The illustrations are for a small bracket but i have cut 3 foot.