Keep plenty of extra blades on hand, as cutting metal will degrade a blade faster than cutting a softer material like hardwood. If you are not using plywood and instead are using cutting oil to lubricate the surface and blade, make sure you’re only applying it an inch or two at a time. More than that, you risk obscuring your guideline.

When cutting a flat sheet of steel or other metal, it’s often recommended to sacrifice a few thin sheets of plywood to sandwich the metal. This creates a more controlled and thus smoother cut by minimizing vibration and keeping the material flat. Metal Cutting TipsLike most saws, jigsaws can also cut through other common building materials, including metal, with the right blade. Use a bi-metal blade with 21-24 TPI on mild steel and softer metals such as aluminum, and use a carbide grit blade on tough alloy steels for best results. Possible other options: cutting oil, thin plywood, drill with a metal pilot bit large enough to fit your jigsaw blade for internal profiles. Move slowly, letting the machine dictate the pace. Forcing the saw to go faster will only degrade your blades and tool motor faster. Jigsaws are highly versatile tools, with their own ranges of options and features. However, for this application there are some limitations to keep in mind for your project:

You can use a jigsaw to cut sheet metal and metal pipes made of cast iron, steel, copper, aluminum, brass, etc. But before jumping in on this project, let’s talk about the safest ways to do it and how you can cut metal efficiently. Safety First Set up your workspace. Use a somewhat high but comfortable working surface. You don’t want to be bent over a short painter’s bench to do this project. If indoors, make sure you have a work light or strong headlamp to illuminate your project while cutting. Move other scraps or project pieces away from your cutting area, and make sure the floor beneath you is clear of cords or tripping hazards. Jigsaw blades have a single row of teeth along one edge of the blade, these are arranged in a small wave pattern from left to right- a blade with 21-24 tpi is recommended for cutting metal and one manufactured with a bi-metal construction will offer the best durability. How do you cut metal straight with a jigsaw? If you are cutting a straight line, consider using a fence or other straight edge (spare 2×4 even) to guide your jigsaw along. Jigsaws are excellent at precise, detailed cuts, but this also means that a small departure from your guideline will be more obvious from a tiny jigsaw blade than with a larger circular saw blade.

When switching your blade to a metal-specific one, make sure that your tool is set for the blade to cut straight and not angled from a previous project. Additionally, make sure your speed is set to slow. You will get the best results from your jigsaw and blades by cutting metal slowly and steadily. Limitations of Jigsaw Drill Start Hole: If you aren’t starting from the edge of the metal, use a drill with a metal-specific pilot bit to create a guide hole in the “waste” side of the piece close to your line. Wear appropriate PPE, this should include eye and ear protection and good quality gloves. The cut off metal will fall, it is prudent to wear sturdy, reinforced toe work shoes or boots.

For cutting metal with a jigsaw, a blade with 21-24 TPI (teeth per inch) is strongly recommended. This will help avoid shredding the material and keep your cut edges smoother. If you have ever attempted to cut thin sheet metal with a jigsaw, you might have noticed excessive vibration, and in some cases, the sheet may get bent and damaged. Working with a jigsaw on metal certainly involves some risk, so here are a few ways to be sure your project is successful and without any “ouch!” ALWAYS make sure your power source is removed when switching blades. Either unplug your corded saw or remove the battery from your cordless saw. Never replace a blade while power is connected, no matter how confident you are. Securely clamp the workpiece to the work bench. If there will not be sufficient depth clearance for the blade, the metal can be placed on rails and then clamped to ensure blade clearance. Some metalworkers ‘sandwich’ the metal sheet between two thin sheets of wood to add support while cutting- this technique will take longer but will help minimise distortion on soft or thin metal.Once the cut is underway, pause the saw and add a few drops of tapping and cutting fluid to the cut to reduce heat at the blade then continue. Apply cutting fluidas required.