01-09-2018, 09:56 AM
Auto hobbyists and handypersons sometimes have the need to cut aluminum sheeting, and don't always have the luxury of going to a metalworking shop to take care of it. Thankfully, aluminum is strong, but not as tough as steel, and sheeting is thin to begin with. 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.
1
Set the piece of aluminum on a table or over sawhorses, and position it so the cutting area has open space underneath it. Clamp the aluminum down.
2
Mark the start and stopping point of your cut with a grease pencil, or some similar implement that marks on sheet metal. With the aid of a ruler or yardstick, draw a straight line between the two marks.
3
Apply a handheld rotary tool fitted with a fiberglass reinforced cut-off wheel accessory to the cutting line. Cut down the line using slow, steady and even pressure. Do not overtly force the tool forward using your main strength, and take care to stay within the line.
Things You Will Need
Table or sawhorses
Clamps
Handheld rotary tool with fiberglass reinforced cut-off wheels
Tip
A power cutting tool fitted with a metal cut-off wheel can perform this task just as well as the handheld rotary tool. Avoid using cutting bits instead of cut-off wheels, however, as they become quickly clogged with bits of aluminum.
Warning
Always wear leather work gloves and safety goggles when cutting any metal, but particularly aluminum. Bits of hot aluminum will fly during this procedure.
1
Set the piece of aluminum on a table or over sawhorses, and position it so the cutting area has open space underneath it. Clamp the aluminum down.
2
Mark the start and stopping point of your cut with a grease pencil, or some similar implement that marks on sheet metal. With the aid of a ruler or yardstick, draw a straight line between the two marks.
3
Apply a handheld rotary tool fitted with a fiberglass reinforced cut-off wheel accessory to the cutting line. Cut down the line using slow, steady and even pressure. Do not overtly force the tool forward using your main strength, and take care to stay within the line.
Things You Will Need
Table or sawhorses
Clamps
Handheld rotary tool with fiberglass reinforced cut-off wheels
Tip
A power cutting tool fitted with a metal cut-off wheel can perform this task just as well as the handheld rotary tool. Avoid using cutting bits instead of cut-off wheels, however, as they become quickly clogged with bits of aluminum.
Warning
Always wear leather work gloves and safety goggles when cutting any metal, but particularly aluminum. Bits of hot aluminum will fly during this procedure.