Cut Through Thin Aluminum Sheet

The illustrations are for a small bracket but i have cut 3 foot.

Cut through thin aluminum sheet.

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. 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. How to cut thin sheet metal and keep it flat.

These photo steps show that it can be done using a utility knife. 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. 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.

If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly. 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. If possible choose a saw blade that creates narrow kerfs the notch or slot made by the saw. Check out this video.