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

[DarkFlame145]

Plasma cutter =P It is a hand held tool.

But cutting a strait line with a hand tool will be hard, but a sawzall would be ok.

But Plasma would be the best way, quick and easy.

[sanddrag]

I've cut (and even plunge cut) 1/4" aluminum plate with a circular saw with a carbide tipped wood blade. While it worked quite well, it was VERY loud, and pretty dangerous. The carbide tips can fly off and pierce safetly glasses even. I wouldn't recommend this.

With any type of saw, you must have the worked secured, go very slowly, and wear ear muffs and a full face mask. They make circular saw blades specifically for cutting non-ferrous metals. Check McMaster.

I'll throw in another vote for the plasma cutter.

[ChrisH]

There are circular saws that can do this. I've cut 6061 plate in excess of 1" thick with one.

BUT....

1) It was at work and the circular saw was the biggest monster i've ever seen. It was very heavy too.

2) Since I got it from the tool crib, it was already set up with a blade and I have no idea what we used.

3) It was loud enough that regular ear protection was insufficient. We used earmufs over ear plugs and that was marginal.

4) It seemed to take forever. The cutting speed was quite slow

A 1/4" sheet won't be as bad but still ... I'd be looking for a really big shear. A local metal supply place might have one that can do the job. They will probably charge a cutting fee but it will be cheaper than a saw.

[ChuckDickerson]

I have never used one but I have been curious about these: http://www.metaldevil.com/ which claim to be a special type of circular saw blade made to do just exactly what you are asking about. If you get one and it works let us all know. It seems like a pretty hand thing for a FIRST team.

[Dick Linn]

There are hand-held circular saws designed for metal cutting. They operate at lower speed than wood saws. They are used with metal cutting blades, which are different for ferrous and non-ferrous metals.

You might get away with a conventional circular saw equipped with a metal cutting blade. I would strongly recommend that you DO NOT use a carbide-tipped blade designed for wood. The carbide is brittle and the relief angles used for wood cutting result in a weaker tooth tip.

It is imperative to guide your cuts and not wiggle of jam the blade. I have a pair of goggles around here where a carbide tooth let loose and poked a hole in them. That was on a miter saw with a metal cutting blade. Do be careful.

[BJT]

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

[Elgin Clock]

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 , and thanks in advance to those who will repost now that I gave the correct info.

[Cory]

Originally Posted by Elgin Clock

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 , and thanks in advance to those who will repost now that I gave the correct info.

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

[FoleyEngineer]

Originally Posted by Elgin Clock

I just measured it, & [b]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?

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

Good luck!

[Qbranch]

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.

[AdamHeard]

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.

[MrForbes]

Yes, my answer changes to be like Adams.

[Dick Linn]

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/