How to Cut Through Thick Sheet Metal

Sheet metal thicker than 11gage -- 1/8-inch -- requires a specialized tool to reduce cutting time and eliminate wasting the blades of tools designed to cut thin metals. Two types of specialized tools are designed to cut thick metal but only one has the ability to cut all types of metal. Both an oxyacetylene torch and a plasma cutter have the ability to cut thick sheet metal but only a plasma cutter can cut all types of metal, including aluminum and stainless steel.

Plasma cutter with built-in compressor
Fire extinguisher
White marking crayon
Green-tinted face shield

Instructions

- 1
  Elevate the thick sheet metal to provide at least 1/2 inch of open area under the cut area.
- 2
  Set a plasma cutter with a built-in compressor near the thick sheet metal. Attach the ground cable running from the plasma cutter to the metal. Turn on the plasma cutter. Place a fire extinguisher near the plasma cutter.
- 3
  Mark the cut on the surface of the sheet metal with a white marking crayon. Ensure the mark is visible when standing 3 feet from the metal. Don a pair of green-tinted face shield.
- 4
  Hold the plasma tip 1/8-inch off the metal, inline with one end of the white line. Depress the trigger of the plasma torch. Pull the torch slowly along the white line. Slow down if sparks shoot toward you. Continue cutting until the sheet metal is cut.
- 5
  Stand near the sheet metal for 30 minutes while keeping the fire extinguisher nearby. Disconnect the plasma cutter ground clamp from the metal before moving either piece of metal.

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