How to Cut Corrugated Sheet Metal

corrugated sheet metal
What You'll Need
Tape measure
Permanent marker
6-inch-diameter cutting wheels
Clutched 6-inch grinders
Safety gear

Corrugated sheet metal can be used for numerous construction projects, from tool sheds to garden sheds, and offers plentiful advantages. However, this metal can be tricky to cut because of its wavy shape. And, using power tools, such as a reciprocating saw or jigsaw, may damage the metal and deform it. Instead, use an electric grinder with cutting wheels and these few steps.

Warning: Put on safety gear before working on this project. To avoid any accidents, wear a face shield, goggles, and safety gloves.

Step 1 – Preparing the Metal

Lay down the corrugated sheet metal on a worktable or any flat area. Make sure your work area is wide, so that you can move freely.


Stretch a tape measure across the sheet and measure the length you need to cut. Using a permanent marker, mark 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 – Setting up the Grinder

Mount the 6-inch cutting wheel to the clutch grinder. It’s extremely important to ensure it’s mounted properly and securely, as it could cut loose and fly around your work area, putting you in danger.

Turning the Grinder On

Then, plug the grinder into a power supply and turn it on. Use the grinder’s top speed. Keep all fingers away from the grinder’s spinning wheel.

Step 4 – Cutting the 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 a potential threat. Change the cutting wheel if it gets too small to cut through the corrugated sheet metal.

Step 5 – Removing Burrs

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. Your corrugated sheet metal is now ready for installation.