To cut straight lines use an electric saw.
How to cut sheet metal with clean edge.
Water jets are surprisingly capable of cutting very thick sheet metal up to a few inches thick with very high accuracy.
Use a die grinder with the mounted point and simply run the point over the edge of the sheet metal.
Good old metal files are great for straightening cut lines in metal edges and for removing burrs and other imperfections.
Also referred to as aviator snips these scissor like hand tools cut sheet metal materials up to 18 gauge in thickness accurately without leaving a ragged bent edge as the finished product.
Secure the sheet metal to prevent slipping.
Run the point over the other sides to break those sharp edges.
They can be used in combination with handheld edge deburrers to produce very clean edges.
If you have to cut a straight line clamp the sheet to a metal table with the edge to be cut just off the table.
The illustrations are for a small bracket but i have cut 3 foot.
Then grip the saw with both hands and push the blade through the metal to cut it.
For thin sheets of metal you can use tin snips to cut through it.
Whether you use an angle grinder or a circular saw the heat damages the edges and the shower of hot sparks can destroy the protective coating and burns the paint finish.
How to cut thin sheet metal and keep it flat.
As the groove in the point wears just move down the point to create a new groove and so on.
Mark your line and clamp a 2 4 or even a yardstick parallel to the edge use the torch head to get the proper spacing and then you have an easy guide to get a clean straight cut.
If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly.
This eats away at the metal and leaves a very clean and smooth edge.
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.
Open the scissors as wide as you can then fit the metal snugly between the blades.
Keep the metal sheet pressed up against the jaws of the snips as much as possible as you cut.
In addition special sheet metal cutting tips are available for specific metals and thicknesses.
