Cut Through Thin Aluminum Sheet

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

Cut through thin aluminum sheet.

If possible choose a saw blade that creates narrow kerfs the notch or slot made by the saw. If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly. Tired of getting fingers cut on sheet metal while using tin snips. Then grip the saw with both hands and push the blade through the metal to cut it.

The illustrations are for a small bracket but i have cut 3 foot. 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. To cut straight lines use an electric saw. For thin sheets of metal you can use tin snips to cut through it.

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. Select a fine toothed blade and don t cut aluminum with a wall thickness of more than 1 4 inch 0 64 cm. Check out this video. Use a wood cutting saw with carbide tipped blades to cut most aluminum.