How to Cut Corrugated Sheet Metal

Corrugated sheet metal can be used for a lot of construction projects such as toolsheds or garden sheds. Corrugated sheet metal can be tricky to cut because of its wavy nature. Learning how to cut it properly will allow you to get the right size and shape for your project. Power tools such as a reciprocating saw or jigsaw may damage the sheet metal because the teeth of the saw will bounce back when they catch the metal and thereby deform it. The perfect tool to use in cutting corrugated metal sheets is the electric grinder with cutting wheels.

Step 1 - Gear Up

Put on your safety gear before working. It’s the number one rule before you start any possibly hazardous task. To avoid any accidents while cutting the sheet metal, you should use a face shield and goggles to protect your face and eyes. Wear leather gloves to keep your hands from being cut; edges of corrugated sheet metal can be razor-sharp. 

Step 2 - Prepare the Corrugated Sheet Metal

Lay down the corrugated sheet metal on a worktable or any flat area. Make sure your work area is wide so you can move freely. Stretch a tape measure across the sheet and measure the length you need to cut. Using a permanent marker, put a mark on the sheet and use a ruler or a straight-edged wood to connect marks if you are going to cut in a straight line.

Step 3 - Set Up the Grinder

Mount the 6-inch cutting wheel to the clutch grinder; make sure it is mounted properly and securely to the grinder. The cutting wheel might cut loose and fly all over your work area. If it can cut through steel, it will have no problems cutting through you, so be extra careful. Plug the grinder into a power supply, turn it on and press the grinder’s trigger up to top speed. Always remember to keep your fingers away from the grinder’s spinning part.

Step 4 - Cut the Corrugated Sheet Metal

Gradually apply pressure on the spinning wheel in front of the metal sheet where you made a line marking. Slowly follow the markings you made on the sheet metal. Do not attempt to push the grinder forward with force, as this can cause the grinder to bounce. Make sure you hold the grinder firmly and always check if the cutting wheel is running straight. If you twist it, the wheel may shatter and the debris will pose potential damage to you. Change the cutting wheel if it gets too small to cut through the corrugated sheet metal.

Extra Tip

After cutting the corrugated sheet metal, tilt down the grinder wheel and drag it at the part you have cut to remove the burrs from the edge of the metal.