How to Cut Aluminum With a Circular Saw


Aluminum has many uses but may need to be cut to the correct size depending on its application. Cutting aluminum typically is done with tools such as cutting shears or by using a chop saw. However, aluminum also can be cut with a circular saw. Before cutting aluminum with a circular saw, determine what type of aluminum you need to cut, such as aluminum siding or an aluminum sheet.

Things You'll Need

  • Saw horses
  • Clamps
  • Tape measure
  • Felt tip marker
  • Straight edge
  • aluminum-cutting blade
  • Extension cord
  • Place the piece of aluminum you need to cut on a pair of saw horses. Secure the aluminum to the saw horses with a clamp.

  • Measure the piece of aluminum with the tape measure. Make a mark with the felt tip marker where it will need to be cut.

  • Place a straight edge over the mark, and make a cut line for the circular saw using a marker.

  • Take the old cutting blade off the circular saw, and attach the carbide or aluminum cutting blade.

  • Adjust the depth of the saw blade to the thickness of the aluminum. If the blade is not deep enough, you will not have a clean cut.

  • Plug the power cord for the circular saw into an electrical outlet or extension cord. Place the front edge of the saw's foot (base plate) onto the aluminum workpiece. Press the trigger on the saw and allow the blade to reach full speed, then slowly engage the blade into the aluminum.

  • Continue pushing the saw slowly until you have cut through the aluminum.

Tips & Warnings

  • Wear safety goggles or a face shield when cutting aluminum to protect against airborne debris.
  • Wear heavy work gloves at all times when working with metal.

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  • Photo Credit the part of circular saw with sharp tooth image by Valentin Mosichev from
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