Best way to do sheet metal work

[GregFrench]

I want to make some trim pirces out of diamond plate. What tools should I get to make clean cuts? I can use my sawzall, but the cuts are rough.

 

[450 DUDE]

You might try a good jig saw with the correct blade.
and follow up with a flap wheel to get it nice and smoove.

oh ya, tip ;if you didnt know cut on the back side of the stuff


ken

 

[Mace]

circular saw with a metal blade.

Or angle grinder with a thin metal blade.

 

[GregFrench]

Guess I would just need to practice to get it smooth.

How about round holes for gauges...something like 3-3/8? I imagine a drill with a round holw-cutting blade might work.

I was just wondering if there was a tool made specifically for cutting and shaping sheet metal that is affordable to a regular person.

 

[450 DUDE]

You could use knock outs,hole saw,flycutter.

I normally use A hole saw.


ken

 

[IBCRUSN]

band saw, Jig saw, hole-saw (depends on the size you start with) to rough size and fine tune with a vertical belt sander, electric grinding wheel with flapper sanding disc or a file.

For sure use the correct TPI if your going to use a jig saw or band saw, that will make finishing much easier.

 

[Exiled]

Flap wheel is your friend! I have a 4" grinder that has a flap wheel permanently on it, I use it all the time! Last week I sharpened a couple of axes and a machete with it. With some patience, it worked like a charm!

 

[Radd Cruisers]

Flap wheel comes in many grits, for aluminum i would use 120 grit.

For strait smooth cuts, circular say and a strait edge as a guide work best for me then as Henry mentioned smooth it off with a flapper wheel.

Rob

 

[srplus]

circular saw with a straight edge to run it against to keep the cuts straight as an arrow... good bosch jig saw or band saw ... T-101 bimetal blade for Bosch jig saw. Belt sander makes it look perfect when done and you can put a slight radius on the edge with no problem. Belt sander smooths out cuts with jig saw.

Hole saws are the only way to get really pretty cuts for gauges that I can think of.

 

[Walton]

Band-Saw with a skip tooth blade for aluminum...

 

[Walton]

If you want the ' Cat's Meow ' ...get a plasma cutter...