Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

A 4.5 inch angle grinder with a cutoff wheel works quite well. the cutoff wheels look just like grinding wheels but thinner.

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

All,
Thank you for all the great responses!

I was mistaken when I made this original post at work today.
I found it strange that there were so many posts saying how dangerous it was to do what I wanted to do with a simple hand tool, or advising something a little beefier when I knew what the plate looked like, & what (thicker aluminum material) we've cut on the team with other tools.

I made a mistake with my measurement I originally stated since i tried to recall what it was while at work and not while the piece was in front of me.
I just measured it, & the metal is only 1/8" thick (actually more like .130" - thicker across the treads of course since it is diamond plate).

Does that change anyone's answers?

Sorry for the call to repost advice :o, and thanks in advance to those who will repost now that I gave the correct info. :)

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

Shear it. We have a piece of junk JET shear, and we can easily do 1/8" aluminum.

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

No. In fact, it's even easier to cut 1/8" diamond plate with a jig saw.

Good luck!

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

Safest: Sawzall
Quickest: Plasma Cutter
Unsafest: Circular Saw
Most Impressive: Huge sheet metal shear
Least Plausible: Willing the material into severance by directing your thoughts

-q :]

p.s. Reccomended: Sawzall or Plasma torch.

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

Shear will give you the fastest, cleanest cut. I'm sure a lot of local places have one (more than just sheet metal shops), and if this is for robotics, would be willing to help out.

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

Yes, my answer changes to be like Adams.

Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
 

A shear would do it in a jiffy.

For reference, here is one brand of metal cutting saw blades (Morse Metal Devil):

http://www.mkmorse.com/

http://www.metaldevil.com/