If you are not using plywood and instead are using cutting oil to lubricate the surface and blade, make sure you’re only applying it an inch or two at a time. More than that, you risk obscuring your guideline. You can use a jigsaw to cut sheet metal and metal pipes made of cast iron, steel, copper, aluminum, brass, etc. But before jumping in on this project, let’s talk about the safest ways to do it and how you can cut metal efficiently. Safety First If starting the cut at the edge, press the saw shoe firmly on the surface of the workpiece without the blade touching the metal. Slowly depress the trigger and once the blade is moving, glide it into the workpiece. It is important not to force the speed of the cut and just let the blade do the work. If starting the cut away from the edge of the workpiece, simply drill a hole large enough to insert the blade in and continue as above. The body of a bi-metal blade is made with spring steel or flexible carbon steel. But the cutting teeth are made of hardened high-speed steel that is welded or diffusion bonded onto the softer body. So the blade can cut harder materials without wearing down as fast.

Keep plenty of extra blades on hand, as cutting metal will degrade a blade faster than cutting a softer material like hardwood. For cutting metal with a jigsaw, a blade with 21-24 TPI (teeth per inch) is strongly recommended. This will help avoid shredding the material and keep your cut edges smoother. Tungsten carbide, which is produced by sintering tungsten and carbon atoms, is a much harder material than steel. A tungsten carbide jigsaw blade is made of a steel blade with tungsten carbide grits on the cutting edge.

Wear appropriate PPE, this should include eye and ear protection and good quality gloves. The cut off metal will fall, it is prudent to wear sturdy, reinforced toe work shoes or boots. Jigsaw blades have a single row of teeth along one edge of the blade, these are arranged in a small wave pattern from left to right- a blade with 21-24 tpi is recommended for cutting metal and one manufactured with a bi-metal construction will offer the best durability.

If you have ever attempted to cut thin sheet metal with a jigsaw, you might have noticed excessive vibration, and in some cases, the sheet may get bent and damaged. Jigsaws are not suitable for plunge cutting metal, however, a hole can be drilled to feed the blade through and then the cut can be continued in the usual way. Jigsaws have good manoeuvrability which makes them ideal to cut quite intricate shapes;, on tight curves it is advisable to make relief cuts to reduce the risk of the blade binding, however, this will only be possible if the cut off side is scrap, otherwise, it may be possible to get as far into the curve as possible and then withdraw the blade and approach the curve from the uncut end. Working with a jigsaw on metal certainly involves some risk, so here are a few ways to be sure your project is successful and without any “ouch!” The hard carbide gits are bonded to a steel shaft by brazing, and usually, the blade has grit like sandpaper but has no cutting teeth that are found on HSS or Bimetal blades. This makes a nice smooth cut on the hardest of materials, but also makes these blades expensive. Jigsaws are awesome, versatile tools. They can make tight, precise cuts, and long straight runs with no distinction from a circular saw’s cut.When cutting a flat sheet of steel or other metal, it’s often recommended to sacrifice a few thin sheets of plywood to sandwich the metal. This creates a more controlled and thus smoother cut by minimizing vibration and keeping the material flat. Metal Cutting Tips How do you cut metal straight with a jigsaw? If you are cutting a straight line, consider using a fence or other straight edge (spare 2×4 even) to guide your jigsaw along. Jigsaws are excellent at precise, detailed cuts, but this also means that a small departure from your guideline will be more obvious from a tiny jigsaw blade than with a larger circular saw blade.

As with most cutting tools, the type of blade you use is possibly the most important factor in how efficient your cuts will be. Whether cutting curves or lines with a jigsaw, ensuring you have the right blade for the application is essential for making clean, safe, and effective cuts. Specific materials require different types of jigsaw blades, including those with varying tooth pitches, sizes, and orientations. For example, blades with fine teeth are ideal for cutting metal, while those with larger teeth are more suitable for wood. Having the right blade for the material you’re working on will always ensure for maximum cutting performance. Jigsaws are highly versatile tools, with their own ranges of options and features. However, for this application there are some limitations to keep in mind for your project:

Like most saws, jigsaws can also cut through other common building materials, including metal, with the right blade. Use a bi-metal blade with 21-24 TPI on mild steel and softer metals such as aluminum, and use a carbide grit blade on tough alloy steels for best results. Proper Support for the Workpiece: Keep your intended blade path as close to your work surface as possible while being aware of your depth and the width of the jigsaw shoe. This minimizes the vibration and sway of your piece and ensures a cleaner cut. This combination of a flexible body and hard cutting teeth makes them last almost ten times longer than blades made from high-carbon steel and 2 to 5 times higher blade life compared to regular HSS blades. Tungsten Carbide Blade When switching your blade to a metal-specific one, make sure that your tool is set for the blade to cut straight and not angled from a previous project. Additionally, make sure your speed is set to slow. You will get the best results from your jigsaw and blades by cutting metal slowly and steadily. Limitations of Jigsaw