How to Cut Aluminum like a Pro

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Check out this blog post to learn how to cut aluminum like a pro! You’ll be surprised at how easy it is to get professional-looking results.

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If you’re like most people, you probably think of aluminum as being a soft, easily cut metal. After all, it’s used in foil, and those foil wrappers are easy to tear. But when it comes to other types of aluminum, such as the type used in siding, gutters and window frames, you might be surprised to learn that it’s actually quite tough. That’s why cutting it can be such a challenge – but fortunately, there are ways to make the job easier. With the right tools and techniques, you can cut aluminum quickly and easily – let’s take a look at how it’s done.

The Right Tools

If you’re looking to cut aluminum like a pro, you need to have the right tools. A good saw is a must, and you should also have a drill, a jigsaw, and a grinder. With the right tools, you can cut aluminum easily and safely. Let’s take a look at the best tools for cutting aluminum.


One of the most versatile tools in a woodworker’s arsenal is the jigsaw. These orbital action powered saws can handle a wide variety of tasks, from straight and curved cuts in wood andmetal to scrollwork and intarsia. Even better, they’re relatively inexpensive, so you can buy one without breaking the bank.

When it comes to cutting aluminum, however, you need to take a few extra steps to ensure that your jigsaw can handle the material. Aluminum is a softer metal than most, which means it’s more likely to clog up your saw blade and cause it to overheat. Fortunately, there are a few things you can do to prevent this from happening.

First, make sure you choose the correct blade for your jigsaw. If you can, find a blade that’s specifically designed for cutting aluminum. These blades have larger teeth with deeper gullets (the spaces between the teeth) that help to clear out chips and debris more effectively. Second, apply light pressure when cutting and avoid making too many curves or turns — both of these things will cause the blade to heat up more quickly. Finally, be sure to lubricate your blade regularly with oil or WD-40; this will help to keep it cool and prevent it from gumming up.

With these tips in mind, you should be able to cut aluminum with your jigsaw like a pro!

Coping Saw

If you’re looking to get clean, intricate cuts in aluminum, a coping saw is the tool for you. A coping saw is a hand-held saw with a thin, sharp blade that’s ideal for making detailed cuts in metal.

To use a coping saw, first mark the metal where you want to make your cut. Then, clamp the metal in place so it doesn’t move while you’re cutting. Next, insert the blade into the metal at a 90-degree angle and start cutting along your marked line. As you cut, be sure to apply even pressure and move the saw back and forth to avoid breaking the blade.

When you’re finished cutting, release the clamp and remove the blade from the metal. Finally, use a file or sandpaper to smooth out any rough edges on your cut.


A hacksaw is a hand tool that can be used to cut metal. It consists of a blade with teeth that are designed to cut metal, mounted on a frame. Hacksaws typically have a comfortable handle that can be gripped by the user’s hand, and a trigger that releases the blade so that it can be moved.

Hacksaws are relatively easy to use and can be very effective at cutting metal, especially if you use the right blade for the job. Be sure to read the instructions that come with your saw carefully before using it, and always wear safety goggles when operating it.

The Right Blades

No matter what kind of saw you use, the key to success when cutting aluminum is having the right blade. This is because the metal is so soft that it easily clogs blades, making them overheat and wear down quickly. You need a blade that will stay sharp and resist clogging.

Jigsaw Blades

Jigsaw blades are specially designed to cut compound curves and tight radii, making them ideal for HVAC ductwork and intricate metal artwork. Jigsaw blades are available in a wide range of sizes, shapes, and tooth configurations to suit your particular cutting needs, so be sure to choose the right blade for the job.

The key difference between jigsaw blades is the tooth count, which is typically between 18 and 24 teeth per inch (TPI). The more teeth on the blade, the smoother the cut will be, but the slower the blade will cut. High-speed steel (HSS) blades are good for general purpose cutting, while bi-metal blades are designed for increased durability and longer life.

There are also specialized jigsaw blades available for cutting aluminum, stainless steel, and other difficult-to-cut materials. When choosing a blade for cutting aluminum, look for one with a low TPI (12 or 14 TPI is ideal) to minimize heat build-up and prevent the blade from getting too hot during use.

Coping Saw Blades

There are different types of coping saw blades to suit different tasks, but the most common is the plain-end blade. It has no teeth on the end, so it can be used to start a cut in the middle of a workpiece. The other type is the pin-end blade, which has teeth on the end and is used to cut curves that start and end on the edge of a workpiece.

Coping saw blades are made from carbon steel or high-speed steel (HSS), and they come in a variety of sizes and shapes. The most common sizes are 10, 12, 14, and 16 tpi (teeth per inch). The teeth can be either regular or skip- tooth style. Skip-tooth blades have fewer teeth and are used for more aggressive cuts, while regular blades have more teeth and are used for finer cuts.

When choosing a coping saw blade, there are a few things to keep in mind. First, choose a blade that’s appropriate for the material you’re cutting. Carbon steel blades are good for general purpose cutting, but HSS blades are better for cutting tougher materials like stainless steel or aluminum.Second, select a blade with the right number of teeth per inch (tpi) for the job at hand. If you’re not sure which tpi to choose, err on the side of too few teeth — it’s always easier to remove material than it is to add it back! Finally, make sure that the blade you select is compatible with your coping saw.

Hacksaw Blades

The first step in choosing the right hacksaw blade is to select the correct length. The length of the blade is determined by the depth of the cut you need to make. If you need to make a cut that is less than 2” deep, you will need a 12” blade. For cuts that are 2” to 3” deep, you will need an 18” blade. And for cuts that are more than 3” deep, you will need a 24” blade.

Once you have selected the correct length blade, the next step is to choose the right teeth per inch (TPI). The number of TPI will determine how fast or slow the blade will cut through the aluminum. For example, a 14 TPI blade will cut through aluminum much faster than a 24 TPI blade but it will also create more of a coarse finish. If you need a smooth finish, you should choose a 24 TPI blade.

Some hacksaw blades are made from high carbon steel and some are made from bi-metal. High carbon steel blades are less expensive but they also wear out faster and they can’t be used on harder metals like stainless steel. Bi-metal blades are more expensive but they last longer and can be used on a variety of different materials including stainless steel.

If you plan on cutting aluminum regularly, it is worth investing in a good quality hacksaw with bi-metal blades. This will save you time and money in the long run.

The Right Technique


A jigsaw is a versatile power tool that can be used for a variety of projects, including cutting aluminum. When using a jigsaw, it’s important to use the right blade for the material you’re cutting and to use the correct technique.

To cut aluminum with a jigsaw, start by clamping the piece of aluminum you want to cut to a work surface. Then, use a pencil to mark the line you want to cut on the aluminum. Next, install a blade designed for cutting metal into your jigsaw. When doing this, make sure that the teeth of the blade are pointing down when they come into contact with the aluminum.

Once the blade is installed, position the jigsaw on the line you marked and turn it on. Guide the blade slowly along the line as you apply gentle pressure. If you’re cutting through thick aluminum, you may need to make several passes with the saw. When you’re finished, unplug the saw and remove the blade.

Coping Saw

One of the most versatile tools you can have in your shop is a coping saw. This simple tool can be used to make all kinds of cuts in aluminum, including compound cuts, curves, and circles.

To use a coping saw, start by clamping the workpiece in a vise or other holding device. Then, use the saw to cut along the marked line. Coping saws cut on the upstroke, so be sure to apply pressure on the downstroke.

If you’re cutting a curved line, it’s best to start at the inside of the curve and work your way out. For best results, use a sharp blade and make sure the teeth are pointing in the right direction (toward the handle).


To cut aluminum with a hacksaw, start by clamping the aluminum to a workbench so it’s secure. Then, use a sharp hacksaw blade to make a series of evenly spaced cuts through the aluminum. Once you’ve made your cuts, use a file to smooth out the edges of the aluminum. If you’re having trouble cutting through the aluminum, try using a lubricant like WD-40 or soapy water to help the blade move more smoothly.


There you have it – our guide to getting professional looking results when cutting aluminum! Remember to use sharp blades, work slowly and carefully, and use a oil or coolant to keep your work area lubricated and prevent the material from overheating. With these tips in mind, you should be able to create clean, precise cuts that will give your projects a polished look.


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