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.

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. 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. 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.

Check out this video. 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. Select a fine toothed blade and don t cut aluminum with a wall thickness of more than 1 4 inch 0 64 cm.

Use a wood cutting saw with carbide tipped blades to cut most aluminum. These photo steps show that it can be done using a utility knife. For thin sheets of metal you can use tin snips to cut through it. The illustrations are for a small bracket but i have cut 3 foot.