Cutting 26 gauge galvanized sheet metal

AndyM · Oct 4, 2019

I need to make a number of fairly long cuts (ideally nice and straight).

I have snips (seems like a lot of work), a 10'' sheer (might be tough with sheet 48 x 120), circular saw (have a metal cutting blade though not sure if it's the right choice for this) or a 4 1/2' grinder with a metal cutting blade.

What say the experts?

edited sheer from 10 FEET to 10 inches!

techcrewkevin · Oct 4, 2019

I would strap a straight edge on that sheet, and use a metal nibbler.

Amazon probably has some cheap ones.

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BobbyK · Oct 4, 2019

Depends if you need the galvanization intact on the cutting edge.
Using a cutting disc will prob burn up the galvanization.
A Pneumatic nibbler or shear would be best to keep the coating intact.
Get a buddy to help and use the shear... bribe him with a beer

I bought a nibbler from Princess Auto and it works great!
This one.
https://www.princessauto.com/en/detail/air-nibbler/A-p8036216e;jsessionid=ypa1jHqmbFCsCXlo4qDV8M+w.pal-prod-com3

Missouribound · Oct 4, 2019

26 ga?
A grinder with a metal blade or a shear will most likely give you the smoothest cut.
The circular saw will be faster but no nearly as neat.
It it was me, I would get a straight edge to clamp to the sheet and use the angle grinder with a cut off blade.
But you said you had a 10' shear? Wouldn't that be the cleanest and fastest?

AndyM · Oct 4, 2019

Thanks all. I do also have a nibbler but i had kind of ruled it out as it cuts a little circle that leaves a bit of a ragged edge. Not sure if it's just mine or if they all do that. Might have to try a little test.

The shear was my first thought but handling the big sheet made me wonder how that would work out. Getting an extra pair of hands is a good idea but is not so easy (or creates other issues). May have to think a little harder on how I could to manage that sheet. My shear is only 10 inches.

I lean a little to the angle grinder but it too has it's challenges - I guess any method of cutting loses the galvanization on the edge - yes?

Thanks.

atitus · Oct 4, 2019

I recently used a power shear to make some fairly long cuts, 22 ga triple galvanized steel. Worked great. With a guide, should be fairly easy to keep it straight. Makes pretty clean cuts. This is what I used, worth every penny.

https://www.harborfreight.com/14-gauge-5-Amp-Heavy-Duty-Metal-Shears-64609.html

SidecarFlip · Oct 4, 2019

Been buying HF Bauer tools for a while now. Good stuff, have not broke one yet. Me, I'd use a straight edge and my Hypertherm Plasma cutter with Fine cut consumables.

Don't think you are gonna spend 5 grand to make one cut though....

AndyM · Oct 4, 2019

I always look to justify a new tool purchase with the rational the first use is less than I would pay a contractor so it's freebee! The powershears fits that very nicely; the plasma cutter (I considered a MUCH smaller one than yours Sidecar) has just never made it through that hurdle. Nice thought though.

Will have to do a little checking on a local version of the powershear (Princess Auto is our HF).

Thanks all.

torch · Oct 5, 2019

I have both the nibbler pictured and the Canadian Tire version of the power shears. The nibbler is great for curves, the power shears great for straight lines.

I also have a plasma cutter. It's just overkill for 26ga sheet metal.

gas man · Oct 5, 2019

straight edge and a good utility knife, score it good, then snap it

mikester · Oct 5, 2019

gas man said:
straight edge and a good utility knife, score it good, then snap it

Yup.

Another alternative is to use a skilsaw with a metal cutting blade and straight edge.

AndyM · Oct 5, 2019

gas man said:
straight edge and a good utility knife, score it good, then snap it

I wondered if something like that was possible. Interesting idea.

I am kind of intrigued by the power sheer idea (I mean who doesn't want a new tool!). Any views as to air vs AC driven?

Yooper · Oct 5, 2019

Find a fab shop or a HVAC business that has a shear and offer to pay them cash. This is such a simple and fast job that I'm sure you will find a place to take it on for 'beer money'. The HVAC shop would be the best bet because their shear would be set up for the thin 26 gauge commonly used for ducting. The edges will be superior to anything you can do by hand.

atitus · Oct 5, 2019

AndyM said:
I wondered if something like that was possible. Interesting idea.

I am kind of intrigued by the power sheer idea (I mean who doesn't want a new tool!). Any views as to air vs AC driven?

If you are all invested in an air setup, this can cut tool cost sometimes. However the bosch/dewalt version of those electric shears are around $300. Even if the air version was half that, you'd still be paying a lot.

Tughill Tom · Oct 5, 2019

AndyM said:
I wondered if something like that was possible. Interesting idea.

I am kind of intrigued by the power sheer idea (I mean who doesn't want a new tool!). Any views as to air vs AC driven?

Look at Kett AC Shears. also called Slotting Shears, cuts straight, left,right. take them anywhere, air not so much.

AndyM · Oct 5, 2019

Well it's done. I figured for the price ($65 loons) I would try the AC sheers. I would not be gambling too much. Glad I did; made 4 of the cuts and it went very well. Kind of make me wonder why I didn't buy one long ago as I could have used it many times for smaller stuff.

Thanks to all for the input.

skeets · Oct 5, 2019

What ya buildin ?

AndyM · Oct 5, 2019

What ya buildin ?

Carport is enclosed on 3 sides with metal gate in front. Wanted to put a door of some sort on it but it's an odd duck size. Add to that the problems we have here with unheated enclosed spaces (everything rots or rusts) a gate is was.

Problem is when it rains (happens here a lot) the place fills with water. I am building panels for inside the gate to try keep most of the rain out. At least that's the hope.

GreensvilleJay · Oct 6, 2019

can you take to a 'tinwhacker' shop or 'soffit/fascia' guy ? I'm assuming it's flat sheets NOT corrugated. Those guys can quickly do it.
I've cut a lot of steel roofing with a 4.5" angle grider with thin disc and a steel bar( as guide). All cuts were straight...
I've also got an electric shear,again use a good straight edge, works well.

Jay

techcrewkevin · Oct 6, 2019

GreensvilleJay said:
can you take to a 'tinwhacker' shop or 'soffit/fascia' guy ? I'm assuming it's flat sheets NOT corrugated. Those guys can quickly do it.

I've cut a lot of steel roofing with a 4.5" angle grider with thin disc and a steel bar( as guide). All cuts were straight...

I've also got an electric shear,again use a good straight edge, works well.

Jay

See post 16. He's already bought the tool.

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Cutting 26 gauge galvanized sheet metal

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