Metal sheet questions: scissors and sharp edges

[Renate]

I've got thin sheet metal, and would love to use it, but I don't have scissors or sawing equipment to cut it, and don't know which kind of scissors I need.

And then, when I have managed to cut it (of course already ruined a pair of normal household scissors ), the edges are so sharp that it is impossible to wear it as jewelry.

I can imagine how to break the edges of thicker sheets, but I would like to work with my very thin and soft copper sheet, where filing doesn't help much, it is still dangerous. I then decided to fold it over, or put it into a kind of frame, but that doesn't solve the problem.

To sum it up, my questions are:
What kind of scissors do I need? What do I need to look for?
and
How can I break the edges of very thin metal sheet?

[laura]

Have you tried fine sanding paper? (800-1000 grit)

[Tela]

I haven't worked with sheet, but judging from what I hear others saying- it requires a lot of filing. Maybe Susan will chime in, she's our resident sheet worker.

[christine]

I am just venturing into sheet metal. I use old sewing scissors, they won't cut cloth but will cut 24G copper. I then use my big file on the edges. Corners, I tend to round and smooth. Debating a saw, one of the traditional types or there is a new frame out there supposedly easier to put the blade in. There are also metal shears. Not a lot of help but so far, it is working for me.

[susan]

Hello Renate. I know exactly what you are talking about here, because I have had some similar challenges with working with aluminum sheet. Those darn edges get so sharp that there is that concern of slicing a finger when working with the sheet and worse yet, nicking the skin while wearing the piece.

When I work with sheet metal I almost always use a jewelry saw with 24 gauge or thicker metal. These are inexpensive and really do give a lot of versatility with regard to getting into tight corners that a scissors with metal just can't seem to do well. Like the rolling mill, I was a little shy to work with a jewelry saw, but once I did start I opened up my life to possibilities with the sheet metal. The thing about using a saw (and bench pin) is that the saw blade acts like a file, which subdues those sharp edges that the scissors leaves behind. In fact, you can use a saw blade in place of a file with certain projects.

If using a saw blade is out of the question for you, then I would suggest using a metal shears or heavy duty kitchen shears on straight geometric shapes. Shapes with many curves are a challenge to use with a pair of scissors due to the bulky nature of the opposing blades. For example, use the scissors to make triangle shapes or square shapes instead of a figure eight or round shape. Move your metal instead of moving the scissors while cutting. After you are done cutting out the shape, then use foam backed sandpaper in progressive grits. This takes time, but when you are finished it is well worth it.

Having said all of that, I have used a Dremel or flex shaft with a cylindrical sand paper attachment to attack those edges quickly. Or I will tape down a piece of flat sand paper and then manually drag the edge of the cut metal along the secured sand paper, again in progressive grits.

What grits of sand paper do I use? I use 400 and then progress to 600, 800 and occasionally a 1000. for particularly stubborn edges I will file with a jewelry file in one direction (away from the body) and then start with 240 grit followed by the above progressive grits.

Good luck and show that sheet metal who is boss!!

~Susan

[Tela]

Very good tips, Susan! I'm afraid that the only sheet metal I have worked with was the kind found on cars and that's a whole 'nuther ballgame. I have actually used a "jaws of life" to cut open a car, but I have never cut 24g copper. LOL! (I was much younger and stronger then!)

[susan]

Tela, you would look funny cutting open a Ford pick-up truck with a jeweler's saw!! When you get a chance tell us what you know about working with metal, even if it is automobile metal. Bet you have some great tips.

Susan

[wildivy]

I bought some metal shears which work great with 24 gauge copper,brass and silver sheet. I haven't tried them with thicker gauges. The shears are available at jewelry supply websites for a reasonable price (around $10). I also saw some for sale at Hobby Lobby.

I have also used an old guillotine style paper cutter. It works great for cutting straight strips in 26 and 28 ga. I needed wider copper bezel than I could get from rolling wire in the rolling mill and I was able to cut some 26 ga. strips of copper fairly straight with it-- and the edges were smooth. I think I've even cut 24 gauge copper with it.