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

[Elgin Clock]

I'm sure this has been asked before, but I did search and didn't come up with anything yet.

Anyways, I have some sheets of aluminum diamond plate (slightly used) that I need to cut that are about 1/4' thick.

Some of my cuts will be just to trim some off of the sides the whole way down the ~4x8 sheet, but other cuts will be angled so the piece looks like a rather large triangle shape.

I can lay out a wooden jig to follow (instead of just a line with a sharpie drawn on it for a bit more accuracy) but my question is, what kind of tool & blade do I need?

I want to buy a circular saw anyways, but if I used that what kind of blade would I need?

We've cut metal before on a table saw for the team but I don't have access to that until build season, & I want to get this project finished over the fall/winter time.

Any help would be appreciated. Thanks!

[MrForbes]

I would not try to use a handheld circular saw to cut metal.

A sawzall (reciprocating saw) will work if you guide it well. A sabre saw or jig saw will take a long time to cut it, but will work if you're patient.

Here is a pdf file with info on selecting blades, you'd probably want a 14 tooth, wide, short, metal cutting blade.

[Stephen Kowski]

whenever I cut aluminum with a circular saw or mitre saw I just go buy the absolute highest tooth count blade I can find and use that....they wear down quickly, but normally they are $20 or less so I usually get my moneys worth....if you want you can get blades that are carbide or diamond tipped which should last you longer, they are more expensive than what I am used to spending, but I am normally cutting 1/8" or 1/16" box tubing

fyi be careful when using one of these circular blades for this purpose....personally if it was me and I knew this was 1/4" I would think of something besides a circular saw to use

good luck, don't hurt yourself plz

[EricVanWyk]

Not that you'd consider doing this, but I'd just like to remind people that cutting a half inch block of aluminum with a band saw meant for wood is a bad idea. The molten plastic that accumulates on the block is concentrated lose.

[spazdemon548]

A plasma cutter would be your safest and quickest way to do it. Maybe there's a weld shop in your area?

[Elgin Clock]

What would be the best air tool to cut something like this?
I have a compressor setup, & I didn't even think of that before.

This is my first venture into cutting metal. I have more experience with wood, but as my projects get a little more complex, I may need to invest in some more metal cutting & forming tools anyways.

[MrForbes]

I can't think of a good air powered tool for that, offhand....mostly they work for metals less than 1/8" thick.

Please do look around to see if you can find someone with a plasma cutter, I forgot to mention that....I have at least 3 friends who have them.

[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.

[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.