Cut Through Thin Aluminum Sheet

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

Cut through thin aluminum sheet.

If possible choose a saw blade that creates narrow kerfs the notch or slot made by the saw. 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. 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. 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. Check out this video. Tired of getting fingers cut on sheet metal while using tin snips.

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. How to cut thin sheet metal and keep it flat. 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. These photo steps show that it can be done using a utility knife.