How To Cut Corrugated Metal With A Jigsaw

How To Cut Corrugated Metal With A Jigsaw

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Cutting through corrugated metal sheets with a jigsaw is not much different from how you would use the tool to work with other types of sheet metal.

You’ll be faced with the same challenges as well, such as the noise, vibration, and the need to lubricate the cut – that’s aside from the complications of dealing with the curves and bends of corrugated metal.

If you will be cutting a piece of metal that will go on the roof or be otherwise exposed to weather, there are a few things to keep in mind as well, that we will end up covering in this guide.

TIP!

Keep in mind that there are other power tools out there that can cut corrugated metal faster and more efficiently than a jigsaw but it can be done...

A circular saw, angle grinder or metal nibblers are other tools that work too. Just an FYI!

The Things You Need to Cut Corrugated Metal With a Jigsaw

A Note On Jigsaw Types: You will need a powerful jigsaw, and even more so if you are working with heavy gauge corrugated metal.

Your jigsaw should also have a variable speed setting which is ideal for metal, you will want to select a low-medium speed setting.

Blades: Along with your tool, you will also need jigsaw blades that are designed to cut metal. For smoother cuts, you want a suitable blade with a high teeth count.

Finer blades with anywhere from 21 to 24 teeth per inch will give you the smoothest cuts when running at lower speeds.

You will need a jigsaw blade that’s long enough so that it is not pulled clear of the corrugated metal when you reach a valley.

Do keep in mind that there are blades especially made for specific types of metal. There are jigsaw blades designed for steel, aluminum, iron and other kinds of material but for corrugated metal a general metal blade should be fine.

Supporting The Material: Sawhorses come in really handy when cutting the metal and two of them should provide enough support, just make sure that they are rated for the weight, as many sheets of corrugated metal can weigh quite a bit.

If you are cutting through heavy gauge metal, you will need some cutting oil to lubricate the cut and extend the life of your blade.

Measuring & Marking: To mark a cutting line on sheet metal, you will also need a measuring tape, a straightedge, and some markers (I like Sharpies).

If you are working on roofing steel, you will also need some spray paint, primer or some sort of sealer to prevent rust on the cut end. 

Safety: You will need to put on safety gear when working with metal. Eye protection is a must, and a cheap pair of clear glasses will go a long way in protecting your eyes from metal shards. Gloves and hearing protection are also highly recommended, as well.

Cutting Corrugated Metal With a Jigsaw

Mark the cutting line with a marker. For straight cuts, use a measuring tape to accurately measure the cutting length and mark the top of the ridges so you can line up your straightedge easier. Use a straightedge to mark the cutting line.

Measure And Mark Ridges Of Corrugated Metal

Measure And Mark Ridges Of Corrugated Metal

Secure the metal sheet on a sawhorse, workbench, or off the ground using a piece of lumber.

To minimize frayed edges, try to secure the sheet at both the cut side and the waste side if possible, to keep the vibration to a minimum.

Put the jigsaw at a low speed setting with the orbital action turned off. Attach the right blade, and position the tool along one end of the cutting line before turning on the jigsaw. Wait for the blade to get up to full speed.

Line Up Jigsaw At Edge Of Corrugated Metal

Line Up Jigsaw At Edge Of Corrugated Metal

Slowly push the jigsaw forward, following the cutting line. Cutting sheet metal is slow work with a jigsaw, and even more so if you are working with corrugated metal. Work slowly and methodically.

If you are making a long cut, you may need to apply cutting oil to the blade of the jigsaw to keep the blade cool.

Cooler blades stay sharper and last longer, especially if you are working with metal.

Continue following your cutting line until you get to the end. Make sure that the waste side of the sheet is supported as you finish the cut.

End Of Cut On Metal

Check the cut and clean up any burrs as needed. You will want to seal the end if you want to prevent rust from forming with a sealer, paint, etc.

Cutting Corrugated Steel Sheet for Roofing

Corrugated steel sheets are often used for roofing, exterior cladding and other applications that expose them to the weather. For these cases, steel roofing and trim are best cut with tin snips, shears or nibblers.

TIP!

You can cut this type of metal roofing material with a jigsaw, even though there are better tools out there that can do the job much better.

The process is the same as the above when cutting this type of material, so use the same basic procedures and you should be fine.

If you cut roofing sheets with a jigsaw, you will have to take precautions to make sure that the roof does not prematurely rust.

This is really the major difference between this type of metal roofing and corrugated roofing.

First, you’ll have to sand off the burrs left by the jigsaw – if left on their own, they will rust way before the rest of the roof.

Clean up any burrs and rough edges, and treat them with primer or paint. The same goes for any part of the painted steel sheet that you may have “burned” off with the jigsaw.

Check that the surface of the corrugated roofing sheet is clear of filings after making the cut.

These filings will rust much faster than the rest of the roof, and they will stick to the surface of the material where they will start rust pits.

Starting a Cut In the Middle of A Sheet:

To start a cut in the middle of corrugated metal, you will need to punch out some starter holes large enough for the jigsaw blade to slip into. First, mark out the cutting line on the sheet with a marker.

Draw Cutout Shape In Metal Roofing

Draw Cutout Shape In Metal Roofing

Now that you have marked out the shape, punch out a starter hole with a cold chisel or use a drill and make a pilot hole. Make sure that these holes are large enough for the jigsaw blade.

Make A Pilot Hole

Make A Pilot Hole

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Although you can use a chisel to punch a groove through some of the thinner metal materials, a pilot hole that is drilled will be a much cleaner alternative and you run less of a risk of damaging or denting the metal in the process.

If you do use a chisel, be sure to have something solid (like a piece of wood) on the backside to prevent the metal from denting when driving it through.

Insert the jigsaw blade into one of the starter holes and line up the jigsaw blade with the cutting line.

Turn on the tool and let the jigsaw blade reach the desired speed. Guide the running blade into the material and cut along the cutting line.

Start Jigsaw Blade In Pilot Hole

Keep the sheet metal firmly secured as you make the cut to minimize burrs and keep the cut-out clean and accurate.

After finishing the cut, clean up any burrs and seal the cut edges as needed with a matching paint or enamel.

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About the author

Ryan

I have been in construction nearly my entire life and have a fascination with tools and love when they make my life easier. Match that with my "research addiction" and you create something like this website!

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