CUTTING THIN K&S METALS - WHAT'S BEST?

One can score the sheet with an X-acto blade, then bend the sheet several times and it will break along the score line.  This is only good, of course, for straight cuts.

Even that will cause curling on edge. I don't know of any method of cutting arbitrary shapes that will not leave a curl.  I flatten the sheet as much as possible, then sand or use a needle file to take the curl off.

I think some quality sheet metal snips should do a cleaner job.  (just as an aside, whatever you do, NEVER cut wire with tin snips; that will leave a "nick" in the cutting edge and ruin the snips)

Gary

Perhaps a mat cutter as used in custom framing shops would work.  You'll get a perfectly straight line and can even cut a bevel if you want.  However, the good ones will set you back over $100.

There is a set of 3 tin snips that I used to use that would cut either left turns, right turns, or straight cuts.  The one with the yellow handle was the straight cut. Never had a problem cutting any thickness of sheet metal with it. They might be available in various auto parts stores. Hope that this helps.

Jim

I also have a set of those "aviation" snips.  Certainly it cuts sheet metal well.  However, I do always get a slight curl along the edge.  No problem filing the curl off, but at least my snips are not curl-free.  The curl is not a large amount, only a few mils, but enough to be visible on small detail.  As I mentioned before, I have never found a way to cut ductile metals without some slight curl on edges.

Clamp the metal between two pieces of wood, then cut the whole assembly with a band saw.  

Gene Beaird,

Pearland, Texas