Cut Through Thin Aluminum Sheet

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.

Cut through thin aluminum sheet.

Check out this video. The illustrations are for a small bracket but i have cut 3 foot. 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.

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. If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly. Select a fine toothed blade and don t cut aluminum with a wall thickness of more than 1 4 inch 0 64 cm. Tired of getting fingers cut on sheet metal while using tin snips.

How to cut thin sheet metal and keep it flat. To cut straight lines use an electric 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. These photo steps show that it can be done using a utility knife.