Sandwich Sheet Metal Sawing
Ever gouged up your hand while plowing through sheet metal with a pair of snips? Or been dissatisfied with an uneven, crinkled edge? Next time, try this sacrificial plywood sandwich technique. You'll bid farewell to wavy edges and undeleted expletives, and cut a dead-straight line every time. Here's how:
Clamp the metal between pieces of 1/2-in. or 3/4-in. scrap plywood and clamp on a straightedge to guide a circular saw. Now just saw through the sandwich using a carbide blade. This tip is for cutting thin sheet metal only, not thicker plate steel.
P.S. This sandwich technique also produces great results when you're drilling holes through sheet metal.