{"id":2306,"date":"2023-01-12T17:51:23","date_gmt":"2023-01-12T17:51:23","guid":{"rendered":"https:\/\/mainlywoodwork.com\/?p=2306"},"modified":"2023-01-12T17:51:31","modified_gmt":"2023-01-12T17:51:31","slug":"how-to-cut-metal-with-a-jigsaw-guide-with-pictures","status":"publish","type":"post","link":"https:\/\/mainlywoodwork.com\/how-to-cut-metal-with-a-jigsaw-guide-with-pictures\/","title":{"rendered":"How To Cut Metal With A Jigsaw – Guide With Pictures"},"content":{"rendered":"
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\"Cutting
Cutting Metal With A Jigsaw<\/figcaption><\/figure><\/div>\n\n\n

Jigsaws are commonly associated with cutting wood. But a jigsaw is a very versatile tool and it can actually be very useful when working with metal as well. <\/p>\n\n\n\n

To cut metal with a jigsaw we need to use an HSS or Bi-metal jigsaw blade. Secure the metal on a sturdy working surface, mark the line you want to cut, cut slowly and let the tool do the work. A jigsaw is best used for cutting up to 1\/8″ (3mm) thick metal sheets or up to 1\/4″ (6mm) thick aluminum sheets. <\/strong><\/p>\n\n\n\n

But there is a lot that goes into cutting metal with a jigsaw like what blades to use, dealing with heat buildup and dulling blades, preparing a proper work surface, and what safety gear to use. <\/p>\n\n\n\n

So let’s go through how we cut metal with a jigsaw in detail. <\/p>\n\n\n\n

How To Cut Metal With A Dremel – Step By Step <\/h2>\n\n\n\n

1. Which Types Of Metal Can You Cut With A Jigsaw
<\/h3>\n\n\n\n

A jigsaw is best used to cut flat metal sheeting<\/strong> where the shoe of the jigsaw can rest properly against the flat surface of the metal. This will provide stability and reduce vibration. <\/p>\n\n\n\n

A jigsaw is not the best tool for cutting odd metal shapes like pipes and or table legs,<\/strong> but in a pinch, it will be able to cut through that as well. <\/p>\n\n\n\n

The thickness of the metal a jigsaw can cut through will vary greatly depending on the hardness of the material. <\/p>\n\n\n\n

A jigsaw can comfortably cut through 1\/4″ (6mm) of aluminum <\/strong>sheeting. <\/p>\n\n\n\n

But when cutting a harder metal like steel sheeting<\/strong>, the jigsaw is going to start cutting very slowly after you exceed a thickness of 1\/8″ (3.2mm)<\/strong><\/p>\n\n\n\n

There are some types of steel you would not want to cut with a jigsaw. Hardened steel for example<\/strong> is very hard as the name implies and would be a pain to cut through with a jigsaw. You can technically do it, but it is just too much effort and it will dull your blades in no time. <\/p>\n\n\n\n

But if you are using a carbide-edged blade, it can cut through thin sheets of hardened steel and stainless steel. <\/p>\n\n\n\n

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2. Use A Powerful Jigsaw<\/h3>\n\n\n\n

The cheapest off-brand jigsaws will be able to cut through metal, but it is going to be harder to achieve clean cuts and you will have to invest more time into cutting. <\/strong><\/p>\n\n\n\n

Using a more powerful jigsaw, either an industrial-grade jigsaw or a mid-range jigsaw will make your cuts faster and cleaner, and help you a lot along the way. <\/p>\n\n\n\n

A good example of a good mid-range jigsaw is this BOSCH 7.2 Amp (Amazon)<\/a>. <\/p>\n\n\n\n

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3. Choose A Jigsaw Blade For Cutting Metal<\/h3>\n\n\n
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Bi-Metal Blade, High TPI Metal Blade, Low TPI Metal Blade<\/figcaption><\/figure><\/div>\n\n\n

The image above shows a Bi-Metal blade for wood, didn’t have one for metal right now. But a Bi-Metal blade for metal will still have the same BIM writings on it. <\/p>\n\n\n\n

I have a complete detailed jigsaw blade guide here: Jigsaw Blades 101 – A Complete Guide<\/a><\/p>\n\n\n\n

HSS Jigsaw Blades<\/h4>\n\n\n\n

HSS stands for “High-Speed Metal”. Most of the jigsaw blades we are going to use for metal has HSS written on them close to the shank. <\/strong><\/p>\n\n\n\n

HSS jigsaw blades are less flexible but more durable than the HCS (High Carbon Steel) blades <\/strong>that are used for cutting wood. <\/p>\n\n\n\n

This means that the HSS blades last longer and can cut harder materials like steel,<\/strong> but they are less flexible and will break more easily if you try to cut curves with them. <\/p>\n\n\n\n

Jigsaw blades for metal will range in teet density from 12 TPI (teeth per inch) to 30 TPI+.<\/p>\n\n\n\n

Jigsaw blades with lower TPI 12 – 20 will be more aggressive, <\/strong>can cut through thicker materials, and will cut faster. But they will also leave a more rugged finish on the cut, and get dull quicker. <\/p>\n\n\n\n

Jigsaw blades with higher TPI 20+ should be used to cut thinner materials,<\/strong> they will leave a cleaner cut, but will also cut slower. <\/p>\n\n\n\n

Bi-Metal Jigsaw Blades <\/h4>\n\n\n\n

Bi-Metal jigsaw blades are made of a combination of different metals to enhance the quality of the blade. <\/strong>It is usually made of both HCS and HSS. <\/p>\n\n\n\n

Bi-Metal jigsaw blades are more expensive than normal HSS blades, but they have a durability that is 2-5 times longer than an HSS blade. <\/p>\n\n\n\n

Investing in some good quality Bi-Metal blades for cutting metal is definitely worth it. <\/p>\n\n\n\n

Carbide Edge Jigsaw Blades <\/h4>\n\n\n\n

The carbide edge jigsaw blade (Amazon) <\/a>is probably the most durable jigsaw blade that can cut through the hardest metal of any of the other jigsaw blades. <\/strong><\/p>\n\n\n\n

But it is also the most expensive jigsaw blade,<\/strong> usually costing upwards of 10$<\/strong> for one blade. <\/p>\n\n\n\n

The cutting edge of the carbide blade is made of carbide, which is an extremely durable metal made from carbon and tungsten mended together. <\/p>\n\n\n\n

If you choose to invest in a carbide edge blade <\/strong>for your jigsaw, you can use it for a long time before it gets dull. <\/strong><\/p>\n\n\n\n

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4. Set your working surface<\/h3>\n\n\n
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\"Securing
Securing The Metal On the Working Surface. Should have used 2 clamps but this piece was so small.<\/figcaption><\/figure><\/div>\n\n\n

Setting your working surface properly is extremely important when cutting metal. <\/strong><\/p>\n\n\n\n

First of all, we want to rest the sheet metal on a sturdy flat surface. <\/strong>If the surface is sort of flimsy, the metal will easily start to vibrate during the cut and we do not want that. <\/p>\n\n\n\n

We also have to clamp the down metal to our working surface,<\/strong> preferably with two clamps so it does not rotate during the cut. I prefer using quick-grip clamps (Amazon)<\/a> because they seem to handle the vibrations better and do not come loose during the cut. <\/p>\n\n\n\n

If you are cutting another shape like a pipe, you can secure it in a vise. <\/p>\n\n\n\n

We also want the edge of the metal we are cutting to be as close as possible to the working surface.<\/strong> If for example, the metal sheet hangs 10″ (25cm) off the table we are working at, the metal will vibrate more.<\/p>\n\n\n\n

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5. Mark the Cut <\/h3>\n\n\n\n

We have to mark the cut before we start cutting.<\/strong> I’ve found that a permanent marker works best for metal. <\/p>\n\n\n\n

We want a strong visible line, so we will be able to see the line even if we need to use some cutting oil or coolant. <\/p>\n\n\n\n

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6. Put On Safety Gear <\/h3>\n\n\n\n

When working with power tools and metal we always want to be using safety gear. <\/p>\n\n\n\n

Eye Protection – <\/strong>Always wear eye protection when using any kind of power tool. When I cut metal I can sometimes feel the small metal pieces hitting the skin on my face and hands. <\/p>\n\n\n\n

Hearing Protection – <\/strong>It is a good idea to wear noise-canceling earmuffs when using a jigsaw to protect your hearing. But this will depend on personal preferences and the sound level of the jigsaw. <\/p>\n\n\n\n

Dust Mask – <\/strong>The amount of fine metal dust that is produced depends on what type of blade you use in your jigsaw. But it is always a good idea to wear a dust mask when cutting metal. <\/p>\n\n\n\n

Metal-Toed Shoes – <\/strong>Metal toes shoes are also a good idea to wear when working with metal. Metal is heavy and can drop onto your foot, you can also be unlucky and drop the running jigsaw. <\/p>\n\n\n\n

Gloves – <\/strong>Gloves are a debated topic when it comes to power tools. But a jigsaw does not rotate, and cutting metal with a jigsaw produces a lot of vibration and heat. It is up to personal preference if you want to use gloves or not when cutting metal. <\/p>\n\n\n\n

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7. Start Cutting <\/h3>\n\n\n
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\"\"
Cutting Aluminum With A Jigsaw<\/figcaption><\/figure><\/div>\n\n\n

We have now secured our metal object to a sturdy working surface, our protection gear is on, the cutting line is marked and we are ready to start cutting. <\/strong><\/p>\n\n\n\n

Put your preferred blade in the jigsaw, put it into the socket or put the battery in, and turn it on. <\/p>\n\n\n\n

After you have started the jigsaw it is important to wait 2-3 seconds to let it reach the speed that the jigsaw is set to. <\/strong><\/p>\n\n\n\n

For harder metals, you might want to use a lower speed <\/strong>to reduce the heat buildup. If the blade and metal get too hot it is going to dull the blades real quickly. <\/p>\n\n\n\n

To initiate the cut we rest the shoe of the jigsaw onto the metal first,<\/strong> with a firm grip we slowly approach our marked line with the blade. <\/p>\n\n\n\n

Go very slowly in the beginning and get a feel for how the jigsaw reacts to the cutting. It is going to be very slow on some metals, and it is going to be a lot quicker on others depending on the hardness and thickness. <\/p>\n\n\n\n

The most important thing is that you do not force the cut, <\/strong>this is only going to result in the blade overheating and getting dull, and it will leave a bad cut. <\/p>\n\n\n\n

Cutting metal is very different from cutting wood, it will take a lot longer,<\/strong> so it can take some time to get used to if you have only used the jigsaw to cut wood before. <\/p>\n\n\n\n

Following the line is fairly simple when cutting metal with a jigsaw, you can make a pretty decent cut without using any guides. But it is never going to be 100% straight without a guide. <\/p>\n\n\n\n

If you want a straight cut, you can use a straight piece of scrap wood or metal and secure it with clamps onto the metal surface.<\/strong> Measure the distance from your jigsaw blade to the end of the shoe, that is how far away you want to clamp the scrap wood\/metal from the marked line. <\/p>\n\n\n\n

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8. Should You Use Cutting Oil When Cutting Metal With A Jigsaw<\/h3>\n\n\n\n

For harder metals, it can be a good idea to use cutting oil to avoid overheating the blade and the metal.<\/strong> But this will depend on the quality of the blade, the thickness of the steel, the quality of the jigsaw, and how long the cut is. <\/p>\n\n\n\n

Metal will get very hot when you cut it, so make sure to not touch it with your bare hands right after the cut.<\/strong> Cutting aluminum and softer metals will not get as hot as hard metals but will still produce some heat. <\/p>\n\n\n\n

The jigsaw blade will also be really hot after a cut in metal. <\/p>\n\n\n\n

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9. Finishing Touches <\/h3>\n\n\n\n

Cutting metal will produce a burr. A burr is a rough metal edge on the cut line.<\/strong> We want to clean up this metal because it is sharp and doesn’t look so good. <\/p>\n\n\n\n

To clean the burr<\/strong> we can use a wide range of tools. We can use some sandpaper, a rotary tool with a grinding stone\/carbide burr or we can use an angle grinder with a finishing disc. <\/strong><\/p>\n\n\n\n

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10. FAQ: Cutting Metal With A Jigsaw<\/h3>\n\n\n\n

Can You Plunge Cut With A Jigsaw Into Metal? <\/h4>\n\n\n\n

A jigsaw should not be used to plunge-cut into the metal. It would take a really long time and the blade would probably break before it could penetrate the metal. But you can drill a hole in the metal and start the cut with the jigsaw from inside the hole. <\/strong><\/p>\n\n\n\n

Can A Jigsaw Make Curved Cuts In Metal? <\/h4>\n\n\n
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\"Curved
Curved Cut In Aluminum<\/figcaption><\/figure><\/div>\n\n\n

Making curved cuts in metal with a jigsaw is possible, but it is harder to achieve curved cuts in metal than in wood<\/strong>. In thin metal sheets and aluminum, you will be able to make curved cuts without much problem. A jigsaw is not suitable for cutting curves in thick and hard metal sheeting.<\/p>\n\n\n\n

Bi-Metal jigsaw blades for metal are recommended when cutting curves in metal with a jigsaw. <\/strong> Carbide Edge blades work well too. HSS blades can also cut curves, but they will break more easily because they are not as flexible. <\/p>\n\n\n\n

Can You Cut Wood With A Metal Jigsaw Blade? <\/h4>\n\n\n
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\"Cut
Cut Through Metal And Wood With A Metal Jigsaw Blade<\/figcaption><\/figure><\/div>\n\n\n

A metal jigsaw blade will be able to cut through wood. But at a slower rate than a wood jigsaw blade. A metal jigsaw blade with low TPI (12-20) will have no problem cutting through slender planks of wood. This is very convenient when you want to disassemble something that has metal fastened onto a piece of wood. <\/strong><\/p>\n\n\n\n

In the image above I use a rough 14TPI jigsaw blade for metal to cut through the lid of a chest that did not fit my trash can. After cutting, it fits. <\/p>\n\n\n\n

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Conclusion<\/h1>\n\n\n\n

Hopefully, you learned something about cutting metal with a jigsaw through this article. Cutting metal might seem a little bit daunting in the beginning, but after some practice cuts, you will quickly become comfortable with cutting metal. <\/p>\n\n\n\n

Good luck with your metal-cutting journey. <\/p>\n","protected":false},"excerpt":{"rendered":"

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