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.

Like 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. 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. 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 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. Keep plenty of extra blades on hand, as cutting metal will degrade a blade faster than cutting a softer material like hardwood. 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.

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.

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. Jigsaws are not suitable for plunge cutting metal, however, a hole can be drilled to feed the blade through and then the cut can be continued in the usual way. Jigsaws have good manoeuvrability which makes them ideal to cut quite intricate shapes;, on tight curves it is advisable to make relief cuts to reduce the risk of the blade binding, however, this will only be possible if the cut off side is scrap, otherwise, it may be possible to get as far into the curve as possible and then withdraw the blade and approach the curve from the uncut end. 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. You definitely need specific, potentially expensive blades for metal, all-purpose blades won’t work. 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 TipsJigsaws 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: