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Re: Best hand tool to use to cut sheet metal (aluminum diamond plate)?
Theoretically an air grinder with a 3" wheel might work, but I would not want to do it -slow and dangerous.
A circular saw with a toothed blade is a bad idea. Use a metal-cutting "grinding wheel" type blade (I think they are called cut-off blades) for aluminum if necessary - again, this can get dangerous.
A sawzall is a good choice overall. slow, but relatively safe and efficient.
A professional would use a big shear for 1/4", but that's not exactly handheld. A Plasma cutter is a good second choice, or if curves are involved. Hard to cut straight, butwith guides and careful work it's not too bad.
For small pieces, a hacksaw is probably best.
Don
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