Three Easy Techniques for Trimming Corrugated Metal Sheets

1. 1

   Don a pair of thick gloves and a welding mask. Although the blade guard will shield you from most of the sparks, it's advisable to wear gloves and a welding mask for the maximum level of protection.[1]

   Work in a well-ventilated area, preferably outdoors. The fumes emitted while cutting corrugated metal can be hazardous.[2]

   • You can utilize circular saws when installing customized shelves and sizing them accordingly.[3]

2. 2

   Position your corrugated metal on top of your work surface. A sawing table or a set of sawhorses can be utilized. Ensure that there are no obstructions directly beneath your cutting line, by placing your corrugated metal on top of your work surface.[4]

   • Measure the area that needs to be cut.

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3. 3

   Exchange your saw blade for any blade specifically designed for metal. If required, unlock your blade guard and replace the blade. To do this, loosen the bolt at the center of the blade using a wrench and unscrew it. Remove the flange and pull out the current blade. Insert the new blade into the saw slot and reattach the flange, ensuring to tighten the bolt as tightly as possible.[5]

   • The suitability of your saw blade for metal cutting will be indicated on its side. Any continuous or sharp-toothed blade intended for metal cutting will suffice.
   • A diamond blade will yield the cleanest results, but they tend to be more expensive than a standard circular saw blade.

4. 4

   Support the corrugated metal with your non-dominant hand and commence cutting. Place the base plate of your saw against the edge where you want to begin cutting. Stabilize the metal by applying pressure with your non-dominant hand, holding it at least 2 feet (0.61 m) away from the saw. Engage the saw's trigger and cautiously make your initial incision into the metal.[6]

   • If you feel uneasy about taking a hand off the saw, you can weigh down the sheet metal with a heavy object. Clamps will not prove effective, as the grooves in corrugated metal make it challenging to maintain the necessary tension.

5. 5

   Direct your saw slowly through the metal. Your circular saw will accomplish most of the task since it will be pulled forward by the traction from your saw blade. Direct the saw slowly through the metal and allow the excess piece that you cut to fall freely to the floor.[7]

   • Avoid shifting your circular saw at an angle as you cut. The grooves in corrugated metal will facilitate cutting a straight line, but if you attempt to turn your saw you'll risk losing control of it. This method is most suitable for cutting long lengths of straight lines in corrugated metal.

   Warning: If you encounter kickback from your circular saw, release the trigger and allow it to come to a rest before you attempt to continue cutting.

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1. 1

   Locate a pair of heavy-duty snips that work with metal. Aviation snips, which are also known as compound snips or tin snips, are designed to cut metal and come in various shapes and sizes. They are typically color-coded based on their intended use. Yellow snips are intended for cutting in a straight line, while green snips cut to the left and red snips cut to the right.[8]

   Tip: Yellow snips are specifically designed for making straight cuts. You can use green snips for clockwise cuts and red snips for counterclockwise cuts.[9]

2. 2

   Don a pair of heavy-duty gloves and place your metal on a level surface. You will be handling the edge of the corrugated metal while using snips, so it is essential to wear a thick pair of construction gloves to ensure that you do not cut yourself. Once you have your gloves on, position your metal on a level and sturdy surface.[10]

3. 3

   Grasp the side of the metal sheet and place your snips around the edge. Use your non-dominant hand to hold the side of the metal. This will not only stabilize it to keep it in place, but you will also be able to lift it up as you cut. Hold the snips loosely in your hand and position the two blades around the edge that you wish to cut.[11]

4. 4

   Press and release the shears repeatedly to cut across the metal. Depress the grips of the shears to make a cut into your corrugated metal. Release the grips to free them and push them forward slightly before repeating the process. As you cut, lift the excess portion of metal upwards with your non-dominant hand to create room for your dominant hand to continue cutting.[12]

   • If you're performing it correctly, it will feel like you're cutting with a pair of scissors!
   • Be cautious not to drop the portion that you're holding in your non-dominant hand, as it could cause a loss of control of the shears or result in cutting your arm on the edge.
   • This method is most effective for cutting smaller portions of sheet metal or cutting at an incline.

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1. 1

   Attach a continuous diamond wheel to your angle grinder. Loosen the nut on an angle grinder and remove it. Slide a continuous diamond wheel onto the top of your angle grinder and tighten the flange nut. Secure it in place with the spindle lock by turning it completely to the right until it can no longer turn.[13]

   Tip: You can use a standard continuous wheel if you'd prefer, but corrugated metal will cause it to erode. A diamond blade will maintain its shape and sharpness when working with corrugated metal.

2. 2

   Position the portion that you're cutting over the edge of your work surface. Place your corrugated metal flat on top of your work surface or sawhorses. If it is heavier sheet metal, there is no need to be concerned about securing it. If it is thinner corrugated metal, weigh it down with a heavy object. Alternatively, stacking multiple sheets of corrugated metal on top could work as well.

3. 3

   Tighten the grinder blade and place both hands on top of your angle grinder. Inspect your angle grinder's disc to ensure that it is securely fastened by pulling on the lip of the disc to see if it moves. If there is any movement, lock your disc in place with the spindle-lock button on top. Then use a wrench to tighten the nut in the middle of your disc before releasing the spindle lock. Place both hands on the two handles on top of your grinder.[14]

   • Ensure that your grinder is turned off before tightening the disc.
   • Never remove the safety guard from your angle grinder.
   • Never remove both hands from your angle grinder while using it.

4. 4

   Don your gloves and welding helmet. Not only will the edges of undulating corrugated metal be sharp and jagged, but sparks will also be emitted from the angle grinder. Put on a thick pair of gloves and a protective welding helmet before you commence grinding your corrugated metal.[15]

   • Also wear long sleeves and pants for an additional layer of safeguard against the sparks that will emanate from your grinder.

5. 5

   Grasp the angle grinder at a 45-degree angle towards your metal and power it on. Disengage the safety feature and switch on your angle grinder. Wait for it to reach full power and then firmly apply it against the area where you intend to begin your cut. There is no need to exert excessive force. The friction generated by the blade of the angle grinder will pull it slightly forward. [16]

6. 6

   Gently move the grinder across the path you are cutting. Progress with caution and slowness and ensure that both hands are firmly gripping the handles of the angle grinder. Direct the angle grinder from above and apply downward pressure at a 45-degree angle as you make the cut. Push the grinder through to the end of your metal and allow the excess piece of metal to fall freely to the ground.[17]

   • You have greater control when cutting with an angle grinder, thus enabling you to execute freeform and circular cuts by rotating your grinder slowly as it revolves.
   • Using an angle grinder also has the advantage of creating a smooth edge, since the side of your grinder is designed to cut through materials as well.

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• Hand protection
• Mask for welding
• Rotating saw
• Saw blade for metal

• Nonstop diamond blade
• Angle grinder
• Protective guard
• Welding helmet
• Hand protection

This article was co-authored by Lui Colmenares and by wikiHow staff writer, Eric McClure. Lui Colmenares is a handyman and licensed home improvement contractor for Mr. Handy NYC based in New York City, New York. Lui is trained and educated as an industrial engineer and specializes in carpentry, painting, and general handyman work such as mounting TVs, doorknob and deadbolt installation, furniture assembly, tile repair, and grouting. Mr. Handy NYC prides itself on quality work performed with speed, skill, and punctuality. This article has been viewed 131,021 times. Co-authors: 4

Updated: September 5, 2022

Views: 131,021

Categories: Metalworking

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